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Safety pillar 90-day model area plan
A safety pillar model area plan is a 90-day plan for proving the safety routine on one area of the plant, the model area, before it spreads to every other area. The team moves from reactive work (learning from what already happened) to preventive work (finding hazards before they hurt anyone) and then to proactive work (standards and safe habits): the incident pyramid for the area, a safety cross, near-miss reporting, a hazard hunt, a risk assessment of every task, high risks removed by the hierarchy of controls, investigations, safety standards, safety observations and an audit. This template has the 13-week plan as a Gantt chart in three phases with the owner, deliverable and done-when of each activity, a scoring table to choose the model area from loss data, the team, a KPI board, the day-90 gate, and the expansion plan for months 4 to 12 in three waves, with a worked example.
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A 13-week Gantt chart in three phases with the owner, deliverable and done-when of each activity, from the incident pyramid to the day-90 gate.13-week Gantt planIncident pyramid to standardsModel area scoringTeam rolesKPI boardDay-90 gateExpansion wavesWorked example
When to use it
When to use a safety pillar 90-day plan
- When a plant wants to move from reacting to injuries to finding hazards first, and wants to prove it in one area before asking every team.
- When near-miss reporting, risk assessments or safety walks exist on paper but nobody is sure they work on the floor.
- When an area has had a run of first-aid cases or a serious near miss and needs a structured 90 days, not a poster campaign.
- When leaders want a safety plan they can review every week: who does what, by when, and what done looks like.
How to fill it in
- 1
Choose the model area from loss data
Score up to three candidate areas (five in Excel) on loss data, visibility, team willingness and repeatability, from 1 to 3. Loss data here means injuries, first-aid cases, near misses and high-rated risks. Pick the highest total; on a tie, the higher loss data score wins.
- 2
Name the team and write day 1
Sponsor, pillar lead, the safety coordinator, the area supervisor and operators, and a maintenance technician for guards and lockout points. In Excel, day 1 and the status date set the dates and status of every activity.
- 3
Set the baseline and the day-90 targets
Near misses reported, actions closed on time, high risks open, tasks with a current risk assessment and first-aid and recordable cases. More near-miss reports is the aim at first: it shows people trust the route.
- 4
Run the 13 weeks and update the plan every week
Move a bar if your area needs it, write the week each activity really finished, and add one actual per KPI each week. Late activities turn red in the Excel version.
- 5
Pass the day-90 gate
The sponsor and pillar lead check the six gate items with evidence. If one is not met, fix it before any other area starts.
- 6
Plan the expansion waves
Wave 1 goes to the areas with the same hazards and tasks, with a model area team member coaching the first hazard hunt in each. Each new area runs its own 13 weeks against its own baseline.
The 90-day plan
Week by week: from the incident pyramid to safety standards
The standard plan printed on page 1 and in the Excel version, tagged reactive, preventive or proactive. Days 1 to 30 are weeks 1 to 4, days 31 to 60 weeks 5 to 9 and days 61 to 90 weeks 10 to 13. Move the weeks to fit your area.
| Weeks | Activity | Owner | Deliverable | Done when |
|---|---|---|---|---|
| 1 | Choose the model area and form the team (Setup) | Pillar lead | Team list and area map; area chosen with the selection table | Team named, sponsor agreed, first meeting held |
| 1 to 2 | Draw the incident pyramid for the area (Reactive) | Safety coordinator | 12 months of injuries, first-aid cases, near misses and unsafe conditions by level | Every recorded event in the period is on the pyramid |
| 2 to 3 | Start the safety cross (Reactive) | Area supervisor | Safety cross posted at the team board, one box per day | Filled in every day and reviewed at the team meeting |
| 2 to 4 | Launch near-miss reporting (Preventive) | Safety coordinator | A simple card or QR route, a log, and a reply to every reporter | Every report gets an owner and a due date |
| 3 to 5 | Hazard hunt: walk the whole area (Preventive) | Model area team | Unsafe condition and unsafe act log with photos | Area fully walked and every finding logged |
| 4 to 7 | Risk assessment of every task in the area (Preventive) | Pillar lead | Risk register: task, hazard, rating before and after controls | Every routine and non-routine task has a current rating |
| 5 to 9 | Remove high risks by the hierarchy of controls (Preventive) | Maintenance technician | Action list: eliminate, substitute, engineer, admin, PPE | High risks closed or reduced, interim controls on the rest |
| 6 to 9 | Investigate incidents and serious near misses (Reactive) | Safety coordinator | Investigation report with root cause and actions | Each one has a root cause and similar risks were checked |
| 8 to 11 | Write the safety standards for the area (Proactive) | Pillar lead | Lockout points, PPE by zone, safe work steps for the top tasks, one point lessons | Standards posted where the work is done and the team trained |
| 9 to 12 | Start safety observations (Proactive) | Area supervisor | Observation schedule and log, feedback given on the spot | Observations done to plan for three weeks |
| 11 to 13 | Safety audit of the area and close the gaps (Proactive) | Pillar lead | Safety audit checklist result and gap list | Audit done and every gap has an owner and a date |
| 13 | Day-90 review and decision to expand (Gate) | Sponsor | Day-90 gate sheet, KPIs against baseline, lessons | Gate signed by the sponsor and the pillar lead |
1
- Activity
- Choose the model area and form the team (Setup)
- Owner
- Pillar lead
- Deliverable
- Team list and area map; area chosen with the selection table
- Done when
- Team named, sponsor agreed, first meeting held
1 to 2
- Activity
- Draw the incident pyramid for the area (Reactive)
- Owner
- Safety coordinator
- Deliverable
- 12 months of injuries, first-aid cases, near misses and unsafe conditions by level
- Done when
- Every recorded event in the period is on the pyramid
2 to 3
- Activity
- Start the safety cross (Reactive)
- Owner
- Area supervisor
- Deliverable
- Safety cross posted at the team board, one box per day
- Done when
- Filled in every day and reviewed at the team meeting
2 to 4
- Activity
- Launch near-miss reporting (Preventive)
- Owner
- Safety coordinator
- Deliverable
- A simple card or QR route, a log, and a reply to every reporter
- Done when
- Every report gets an owner and a due date
3 to 5
- Activity
- Hazard hunt: walk the whole area (Preventive)
- Owner
- Model area team
- Deliverable
- Unsafe condition and unsafe act log with photos
- Done when
- Area fully walked and every finding logged
4 to 7
- Activity
- Risk assessment of every task in the area (Preventive)
- Owner
- Pillar lead
- Deliverable
- Risk register: task, hazard, rating before and after controls
- Done when
- Every routine and non-routine task has a current rating
5 to 9
- Activity
- Remove high risks by the hierarchy of controls (Preventive)
- Owner
- Maintenance technician
- Deliverable
- Action list: eliminate, substitute, engineer, admin, PPE
- Done when
- High risks closed or reduced, interim controls on the rest
6 to 9
- Activity
- Investigate incidents and serious near misses (Reactive)
- Owner
- Safety coordinator
- Deliverable
- Investigation report with root cause and actions
- Done when
- Each one has a root cause and similar risks were checked
8 to 11
- Activity
- Write the safety standards for the area (Proactive)
- Owner
- Pillar lead
- Deliverable
- Lockout points, PPE by zone, safe work steps for the top tasks, one point lessons
- Done when
- Standards posted where the work is done and the team trained
9 to 12
- Activity
- Start safety observations (Proactive)
- Owner
- Area supervisor
- Deliverable
- Observation schedule and log, feedback given on the spot
- Done when
- Observations done to plan for three weeks
11 to 13
- Activity
- Safety audit of the area and close the gaps (Proactive)
- Owner
- Pillar lead
- Deliverable
- Safety audit checklist result and gap list
- Done when
- Audit done and every gap has an owner and a date
13
- Activity
- Day-90 review and decision to expand (Gate)
- Owner
- Sponsor
- Deliverable
- Day-90 gate sheet, KPIs against baseline, lessons
- Done when
- Gate signed by the sponsor and the pillar lead
What's on the gates
The day-90 gate and the wave gate for the safety pillar
The day-90 gate decides whether the model area is ready to be copied; the wave gate is checked for each new area before the next wave starts. Both are on page 3 of the PDF and on the Excel version's Day-90 gate and Expansion sheets.
Day-90 gate
All met before the first expansion wave starts
- 1Every task in the area has a current risk assessment
- 2High risks are closed or reduced, with interim controls on the rest
- 3Near misses are reported and every report gets an owner and a reply
- 4The safety cross and the observation routine run without the pillar lead
- 5The KPI board has 13 weeks of data against the baseline
- 6The standards and lessons are written up so another team can copy them
Wave gate
For each new area, before the next wave starts
- 7The area passed the same day-90 gate as the model area
- 8Its KPIs are measured against its own baseline, not the model area's
- 9The risk register, standards and lessons were copied and adapted, and the copy is recorded
- 10Coaches for the next wave are named and have run a session with the pillar lead watching
- 11The model area was audited again and still holds its standard
A filled-in example
Illustrative, not a benchmarkAn example: a metal stamping plant (illustrative, with made-up numbers; the same as page 4 of the PDF and the Excel example sheets). Not a benchmark.
The example model area at week 13: share of each gap closed
- Tasks with a current risk assessment: 20% to 100%100%
- Actions closed on time: 45% to 85% (target 90%)89%
- Near misses reported: 2 to 7 a week (target 8)83%
- High risks open: 6 to 1 (target 0)83%
- First-aid and recordable cases: 3 to 1 (target 0)Lowest67%
Near misses reported 83 percent of the gap closed, actions closed on time 89, high risks open 83, tasks risk-assessed 100, first-aid and recordable cases 67.
- Model area choice, loss data, visibility, team willingness and repeatability scored 1 to 3: Press line 2 scored 11, Weld cell A scored 9 and Shipping dock scored 7. Press line 2 had the most first-aid cases and the highest-rated risks (pinch points at die change), sits on the main aisle, and its tasks repeat on two other press lines.
- Near misses and unsafe conditions reported: baseline 2 a week, day-90 target 8 a week, week 13 actual 7 a week, 83% of the gap closed.
- Safety actions closed on time: baseline 45%, day-90 target 90%, week 13 actual 85%, 89% of the gap closed.
- High risks still open: baseline 6, day-90 target 0, week 13 actual 1, 83% of the gap closed.
- Tasks with a current risk assessment: baseline 20%, day-90 target 100%, week 13 actual 100%, 100% of the gap closed.
- First-aid and recordable cases: baseline 3, day-90 target 0, week 13 actual 1, 67% of the gap closed.
The team passed the day-90 gate in week 13. Wave 1 (months 4 to 6) went to Press lines 1 and 3, wave 2 (months 7 to 9) to Weld cells A and B, and wave 3 (months 10 to 12) to Shipping dock, stores, tool room, with a model area team member coaching each wave 1 area.
Common mistakes
Judging the area by injuries alone
Injuries are rare and lag behind the hazards. Track near misses, unsafe conditions and actions closed as well, or the board will look fine until someone is hurt.
Asking for near misses and never replying
People stop reporting when reports disappear. Give every report an owner and a due date, and tell the reporter what was done.
Fixing every risk with PPE and signs
Work down the hierarchy of controls: remove the hazard, substitute, engineer it out, then procedures, and PPE last.
Writing standards nobody was trained on
A standard in a binder protects nobody. Post it where the work is done and train the team before the observation routine starts.
Spreading before the gate
Copying an unproven routine to every area spreads its gaps too. Hold the gate, then expand in waves.
Download the template
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Run this template in LeanSuite
In LeanSuite near misses, unsafe acts and unsafe conditions are routed to an owner with a due date, every corrective action is tracked to completion, and safety metrics such as near misses show on an SQDC tier board with a safety heat map.
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FAQ
Safety pillar 90-day model area plan: common questions
It is one area of the plant where the safety pillar first runs its full routine with the people who work there, proves it on the floor and writes the standards. The model area team then coaches the next areas, so the routine spreads with people who have done it.
In week 1 the team sorts the area's last 12 months of injuries, first-aid cases, near misses and unsafe conditions into the levels of a pyramid. The wide base of near misses and unsafe conditions shows where to look before anyone is hurt, which is why the plan then starts near-miss reporting and a hazard hunt.
Usually up at first. More reports early on means people trust the route and are seeing hazards they used to walk past. The template sets a target for reports and a separate one for actions closed on time, so reporting and fixing are both tracked.
Start from loss data: injuries, first-aid cases, near misses and the highest-rated risks by area. Then look at visibility, whether the supervisor and team want to work on safety, and whether the same hazards and tasks repeat elsewhere. The template scores each from 1 to 3 and picks the highest total.
When the model area passes the day-90 gate: every task risk-assessed, high risks closed or reduced, near misses answered, the safety cross and observations running without the pillar lead, and the standards written up. Then it spreads in waves, starting with the areas that share the same hazards.
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- Yokoten tracker (horizontal deployment)Copy a proven improvement line by line: the source result, each candidate's own before and after, its share of the source's improvement and the standard updated.
- Coaching kata template (improvement kata storyboard)The learner's storyboard (target condition, current condition, obstacles, PDCA cycles) and a fold-over card with the coach's five questions.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Nemawashi template (stakeholder plan)Plan the one-to-one conversations before a decision: who to talk to in what order, their concerns, what changed and where they stand.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- Future state value stream map worksheetThe eight future-state questions worked through in order: takt, pitch, flow, supermarkets, the pacemaker and the mix, with an EPEI check and current against future lead time.
- Value stream plan (VSM action plan)The future-state map cut into loops, each with an objective and a measurable goal, and its kaizen bursts turned into owned, dated projects on a 12-month timeline.
- Kaizen project plan (Gantt chart)One improvement project as a Gantt chart: tasks by phase with owners, predecessors and working days, a 16-week grid, milestones and a status from planned against actual % done.
- Histogram templateReadings, bins set by the square root rule, a tally and counts, the spec limits drawn and the share out of spec, with the common shapes explained.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Gauge calibration logA gauge register with next due dates and status, a calibration record with as-found and as-left readings, and the steps when a gauge fails.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- TQM self-assessment templateThe eight TQM principles in 24 statements you can check on the floor, scored 0 to 4 by several people, with the spread, the top 3 gaps and an action plan.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.