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Silica exposure control plan template
A silica exposure control plan is the written plan that OSHA's silica standard for general industry requires covered employers to put in place and follow. The standard is 29 CFR 1910.1053 (Code of Federal Regulations), on respirable crystalline silica. Paragraph (f)(2) sets its minimum contents: a description of the tasks that involve exposure, the engineering controls, work practices and respirators used for each task, and the housekeeping measures. The plan has to be reviewed at least once a year and be available to employees. This template is written for foundries, glass plants and other general industry sites, not construction, which has its own rule. It covers the tasks that usually expose people, such as shakeout, sand handling, casting cleaning and grinding, furnace and ladle relining and the glass batch house, and adds the rest of the program around the plan, each part with its paragraph named: exposure assessment against the action level of 25 µg/m³ and the permissible exposure limit (PEL) of 50 µg/m³, both 8-hour time-weighted averages (TWA), regulated areas, respirators, medical surveillance, training and records. It is a starting point, not legal advice: check the standard and any state plan rules where you operate.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for the site, plan owner and review dates, the action level and PEL, and a table of tasks with columns for people, days a year, latest result, engineering controls, work practices and respirator.Tasks and controlsHousekeepingExposure assessmentAction level and PELRegulated areasRespiratorsMedical surveillanceTrainingRecords31-check plan auditTWA calculator
When to use it
When to use a silica exposure control plan template
- When you first write the plan, or when the plan on file was written for construction and does not fit a plant.
- For the yearly review the standard requires, using the 31-check audit to see what has changed.
- After a change in production, process, controls, people or work practices that could raise exposure.
- When new monitoring results come back, to set regulated areas, repeat monitoring dates and who is offered medical surveillance.
- As the silica part of a foundry or glass plant safety checklist, alongside the crane, hot work and lockout sheets.
How to fill it in
- 1
List every task
Walk the plant with the people who do the work. List each task that disturbs sand, refractory, batch or settled dust, with the area, shift, number of people and days a year.
- 2
Assess exposure
Use air monitoring or objective data for each job. An 8-hour TWA is the sum of each sample's concentration times its hours, divided by 8. Compare it with 25 and 50 µg/m³.
- 3
Describe the controls for each task
Write the engineering controls, work practices and respirators for each task, in the order of the hierarchy of controls. Respirators supplement feasible controls; they do not replace them.
- 4
Set regulated areas, monitoring and surveillance
Mark a regulated area wherever exposure is over the PEL. Book repeat monitoring within 3 months for results over the PEL and within 6 months for results from the action level up to the PEL. Offer medical surveillance to everyone at or above the action level on 30 or more days a year.
- 5
Write the housekeeping rules
No dry sweeping or brushing and no compressed air where they raise silica dust, unless the standard's exceptions apply. Name the HEPA vacuums, wet methods and the cleaning schedule.
- 6
Train, share and review
Train every covered employee, make the plan available, tell people their results within 15 working days, and review the plan's effectiveness at least once a year with the 31-check audit.
Reading a result
What an 8-hour TWA result means under 1910.1053
Under the scheduled monitoring option in paragraph (d)(3). The performance option assesses exposure from any mix of air monitoring and objective data instead of a fixed schedule.
| 8-hour TWA result | Where it sits | Monitor again | What else follows |
|---|---|---|---|
| Below 25 µg/m³ on initial monitoring | Below the action level | Monitoring may stop for the employees it represents | Assess again after a change in production, process, controls, people or work practices |
| Below 25 µg/m³ on later monitoring | Below the action level | Within 6 months, until two results taken 7 or more days apart are below it | As above |
| 25 to 50 µg/m³ | At or above the action level, not over the PEL | Within 6 months | Medical surveillance for those at this level for 30 or more days a year, and training |
| Over 50 µg/m³ | Over the PEL | Within 3 months | A regulated area, better controls, respirators until the controls work, and the corrective action in the written notice |
Below 25 µg/m³ on initial monitoring
- Where it sits
- Below the action level
- Monitor again
- Monitoring may stop for the employees it represents
- What else follows
- Assess again after a change in production, process, controls, people or work practices
Below 25 µg/m³ on later monitoring
- Where it sits
- Below the action level
- Monitor again
- Within 6 months, until two results taken 7 or more days apart are below it
- What else follows
- As above
25 to 50 µg/m³
- Where it sits
- At or above the action level, not over the PEL
- Monitor again
- Within 6 months
- What else follows
- Medical surveillance for those at this level for 30 or more days a year, and training
Over 50 µg/m³
- Where it sits
- Over the PEL
- Monitor again
- Within 3 months
- What else follows
- A regulated area, better controls, respirators until the controls work, and the corrective action in the written notice
The yearly plan audit
The 31 checks for a silica exposure control plan
Seven groups, each tied to a paragraph of 29 CFR 1910.1053. Use them for the yearly review of the plan's effectiveness; on the sheet each check is Yes, No or N/A, with the evidence and an action for every No.
Exposure assessment
1910.1053(d)
- 1Every task and job that may involve silica exposure is listed by area and shift
- 2Exposure was assessed by air monitoring or objective data for each job that may reach the action level
- 3Repeat monitoring is booked on the schedule the last results call for
- 4Exposure was assessed again after a change in production, process, controls, people or work practices
- 5Employees were told their results within 15 working days, with the corrective action when a result was over the PEL
Written plan and controls
1910.1053(f)
- 6The written plan describes each task that involves exposure
- 7For each task it describes the engineering controls, work practices and respirators used
- 8It describes the housekeeping measures
- 9Local exhaust, enclosures and dust collectors work as designed and are checked on a schedule
- 10Water sprays and wet methods work where the plan relies on them
- 11The plan was reviewed for effectiveness within the last 12 months and updated where needed
- 12The plan is available to employees and their representatives when they ask
Regulated areas and respirators
1910.1053(e) and (g)
- 13A regulated area is set up wherever exposure is, or could be, over the PEL
- 14Regulated areas are marked off, with the warning sign at every entrance
- 15Only authorized people go in, and each wears the respirator the plan names
- 16Respirator use is covered by a written respiratory protection program under 1910.134
- 17Fit tests and medical clearance for respirator wearers are current
Housekeeping
1910.1053(h)
- 18No dry sweeping or dry brushing where it could raise silica dust, unless wet methods and HEPA vacuums are not feasible
- 19No compressed air for cleaning clothes or surfaces, unless ventilation captures the dust or there is no feasible alternative
- 20HEPA vacuums are on hand and working
- 21Spills from sand systems and dust collectors are cleaned up on the schedule in the plan
Medical surveillance
1910.1053(i)
- 22Everyone exposed at or above the action level on 30 or more days a year is offered surveillance at no cost
- 23New starters in those jobs are offered an initial exam within 30 days of assignment
- 24Periodic exams are offered at least every three years
- 25Each employee gets the written medical opinion within 30 days of the exam
Training and hazard communication
1910.1053(j)
- 26Silica is in the hazard communication program, with labels and safety data sheets available
- 27Each covered employee can explain the health hazards, the tasks that expose them and the controls in place
- 28Training covers the purpose of medical surveillance and what the standard contains
- 29A copy of the standard is available to covered employees at no cost
Records
1910.1053(k)
- 30Each air monitoring record shows the date, task, methods, number, length and results of samples, the lab, respirators worn and the employees it represents
- 31Objective data and medical records are kept and made available as 29 CFR 1910.1020 requires
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a made-up gray iron foundry with a green sand molding line, monitored on 15 September 2026 under the scheduled monitoring option. The same example is page 4 of the PDF and the Example sheet of the Excel file.
8-hour TWA by task against the action level and the PEL
- Ladle and furnace relining (4 people, 12 days a year)95over the PEL
- Shakeout (4 people, 240 days a year)60over the PEL
- Sand system and muller (3 people, 240 days a year)41action level to PEL
- Casting cleaning and grinding (6 people, 240 days a year)38action level to PEL
- Molding line (6 people, 240 days a year)22below action level
- Core room (5 people, 240 days a year)18below action level
TWA = Σ (hours × concentration) ÷ 8
Shakeout operator, three samples over the shift
- (3 × 110 + 2 × 45 + 3 × 20) ÷ 8= 60
Shakeout 8-hour TWA60 µg/m³
Respirable crystalline silica, 8-hour TWA in micrograms per cubic meter: Shakeout 60, Casting cleaning and grinding 38, Sand system and muller 41, Core room 18, Molding line 22, Ladle and furnace relining 95. Action level 25, PEL 50.
- Shakeout operator, three samples over the shift: 3 hours at 110, 2 hours at 45 and 3 hours at 20 µg/m³. TWA = (330 + 90 + 60) ÷ 8 = 60 µg/m³, over the PEL.
- Over the PEL: shakeout (60) and ladle and furnace relining (95). Both become regulated areas with respirators, the shakeout exhaust is reviewed, and both are monitored again by 15 December 2026.
- From the action level up to the PEL: casting cleaning and grinding (38) and the sand system (41). Monitored again by 15 March 2027.
- Below the action level: core room (18) and molding line (22). Assessed again if the process or controls change.
- Medical surveillance: shakeout 4 + grinding 6 + sand system 3 = 13 people at or above the action level for 240 days a year. The 4 relining crew are over the PEL but only 12 days a year, under the 30-day trigger, unless they also work other exposed jobs.
Two tasks over the PEL, 13 people offered medical surveillance and two monitoring dates in the calendar. Each employee gets the results in writing within 15 working days, with the corrective action for shakeout and relining.
Common mistakes
Using a construction plan
Construction plans are built around the task table in the construction rule. A foundry or glass plant is general industry, so its plan follows 1910.1053 and its own exposure assessment.
Respirators instead of controls
The standard puts engineering and work practice controls first. Respirators cover the gap while controls are installed, on tasks where controls are not feasible, and in regulated areas.
Forgetting short, dusty jobs
Relining, dust collector changes and sand system cleanouts happen a few days a year but can give the highest results. List them as tasks.
Dry sweeping out of habit
A broom or an air hose at the end of the shift can undo the controls. Put HEPA vacuums where people need them and say so in the plan.
A plan nobody reviews
The plan has to be reviewed at least once a year for effectiveness. Use the 31-check audit and change the plan when results or tasks change.
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FAQ
Silica exposure control plan template: common questions
Under 29 CFR 1910.1053(f)(2), at least a description of the tasks that involve exposure to respirable crystalline silica, the engineering controls, work practices and respiratory protection for each task, and the housekeeping measures. The plan must be reviewed at least once a year and be available to employees and their representatives.
In general industry the action level is 25 µg/m³ and the permissible exposure limit is 50 µg/m³, both as 8-hour time-weighted averages. The action level triggers exposure assessment and, at 30 or more days a year, medical surveillance; over the PEL you need regulated areas and respirators while controls are improved.
Yes, where workers are exposed to respirable crystalline silica, unless an exception applies, such as objective data showing exposure will stay below 25 µg/m³ as an 8-hour TWA under any foreseeable conditions. Construction work is covered by the construction rule, 29 CFR 1926.1153, instead.
Under the scheduled monitoring option: again within 6 months when results are at or above the action level but not over the PEL, within 3 months when over the PEL, and within 6 months when a later result is below the action level, until two results taken 7 or more days apart are below it. The performance option uses air monitoring or objective data instead of a fixed schedule.
Molten metal and moisture, cranes moving ladles, hot work, lockout on sand systems and machines, noise and heat. Use the overhead crane inspection checklist, the hot work permit and the lockout procedure template alongside this plan.
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- Pre-shipment inspection checklistThe last check before shipping: part, quantity, labels, packaging, paperwork and photos, then release.
- Material shortage logEvery part short with its need date, line impact, ETA and escalation, and counts by reason and supplier.
- Work order template for maintenanceA work order template for maintenance: one form per job from request to handback, and a log of response, completion and backlog by priority.
- Six big losses worksheetWhere a machine's planned time goes: the six big losses in minutes, ranked, with A, P, Q and OEE worked out.
- Andon response logEvery andon call with response and fix times, flags against your targets, and counts by type and station.
- Changeover checklist25 checks for every changeover, a record of planned and actual times, and a log of changeover time against target.
- Kanban sizing calculatorHow many kanban cards each loop needs, per part, with the change from today's cards and what the loop holds in days.
- Kaizen event trackerEvery kaizen event on one sheet: status, roles, the metric against target, open actions and the 30, 60 and 90 day checks.
- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
- Defect check sheetTally defects by type and day, with units inspected, defect rates, a location sheet and the week's Pareto.
- TWI job breakdown sheetThe TWI Job Instruction breakdown of a job into important steps, key points and reasons, with a worked example and the four steps.
- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Maintenance KPI trackerMTBF, MTTR, availability and PM compliance per asset and month, plant figures from the totals, planned maintenance % and backlog in weeks.
- Daily huddle agendaA 15-minute start-of-shift stand-up in six timed blocks, with yesterday's SQCDP results, today's plan, actions and escalations.
- DMAIC project charter templateThe Define-phase charter on one page: problem and goal, metrics, scope, team and phase dates, with savings and a tollgate checklist.
- Water spider route plan (mizusumashi)A water spider's fixed route: stops with arrival times, what is delivered and collected, route time against the cycle, cart load and a trip log.
- Cost deployment matrixWCM cost deployment on paper and in Excel: loss quantities by process, causal and resultant losses, the cost of each loss, a Pareto and the projects that recover them.
- Equipment criticality analysisAssets scored 1 to 5 on six criteria with your own weights, ranked and sorted into classes A, B and C with a safety override and a suggested maintenance strategy.
- Bottleneck analysis worksheetEffective capacity per station from cycle time, parallel units, availability and yield, the bottleneck, takt and utilization, a queue cross-check and the five focusing steps.
- QA matrix templateDefect modes against stations in flow order: where each is made and first caught, a weight × occurrence × detection score, an AA to C class and the escapes flagged.
- Fault tree analysis templateA drawing area with the FTA symbols, an event table with probabilities and minimal cut sets, and the gates worked out bottom-up in Excel.
- Is / is not analysis templateWhat, where, when and extent with is, is not, distinctions and changes, then each possible cause tested against every pair and ranked.
- 5G investigation sheetConfirm the facts before naming a cause: 5W1H, the five G's with 20 prompts, the gap against the principle and the standard, and the countermeasures.
- 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.
- 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.
- 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.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
- Cleanroom audit checklist33 cleanroom checks split by how often they run (each shift, weekly, per plan, system), a gowning order to watch against, a differential pressure log and a findings log, with a worked week of readings.
- GMP audit checklist for drug manufacturing42 self-inspection checks ordered by the subparts of 21 CFR 211, each with its section, the matching EU GMP chapter and whether it is seen on the floor or in records, graded critical, major or minor, with a worked audit of a packaging line.
- Line clearance checklist28 line clearance checks in six sections (area, equipment, materials, printed materials, documents, coder and vision settings), cleared by the operator and verified by a second person, with a printed-materials reconciliation and a worked example that does not balance.
- ISO 13485 internal audit checklist38 questions on ISO 13485 clauses 4 to 8, each with the FDA QMSR section that brings it in or adds to it, a production floor tab (records, current instructions, training, nonconforming product, CAPA) and a worked audit of a catheter line.
- ISO 22716 GMP audit checklist for cosmetics25 cosmetic GMP checks following the sections of ISO 22716, split into a floor walk (people, premises, equipment, materials, production) and system checks (lab, out of specification, deviations, complaints, change control, audits, documents), with a worked audit of a filling line.
- SSOP template: sanitation standard operating procedureOne sanitation SOP sheet per area or machine (steps, chemical, contact time, PPE, lockout, owner), a 23-check pre-op inspection and a verification log for visual, ATP and micro checks.
- SQF internal audit checklist for food manufacturing54 questions in the two parts of the SQF manufacturing code (system elements and GMP), each group mapped to BRCGS and FSSC 22000, graded Conforms to Critical, with findings, a score and a yearly plan.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- ESD audit checklist29 checks for an ESD protected area, with daily tests split from periodic verification, a measurement log and a worked audit.
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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.