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Skills matrix template
A skills matrix is a grid of people against tasks, with each cell showing how well that person can do that task. It shows who can cover what and where one absence would stop the work, so training goes where the gaps are. This template rates each person 0 to 4 (0 not trained, 4 can train others; levels 1 to 4 match the ILUO letters many lean plants use), counts only levels 3 and 4 as cover, and compares that with the cover you need for each task. The Excel version draws the levels as Harvey balls, works out coverage, trainers, the gap, a status and a training priority for every task, splits the cover by shift so a total cannot hide a shift with nobody, and has a training plan in the style of the TWI training timetable that checks whether each row closes a gap, is late, or has a trainer below level 4. The PDF has the blank matrix, the cover-by-shift and training plan sheet, and a filled-in example that matches the Excel.
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A grid of names and shifts against twelve numbered task columns with blank Harvey balls, rows for coverage, trainers, cover needed and gap, and a 0 to 4 level legend with the ILUO letters.0-4 levels with ILUO and Harvey ballsCoverage and trainers per taskCover needed, gap and statusTraining priorityCover by shiftTraining plan with checksWorked example
When to use it
When to use a skills matrix
- To plan cross-training so every critical task has enough qualified people on every shift.
- When covering absences or building the shift plan: who can run this station today?
- Before a quality audit or customer visit that asks for evidence of competence (ISO 9001 clause 7.2 asks you to keep it).
- When a new product, line or machine arrives and you need to decide who to train first.
- When the same one or two people are always called in, or one retirement worries you.
- When you plan who could step into a supervisor or specialist role, to see which tasks each candidate still needs to learn.
How to fill it in
- 1
List the tasks across the top
Stations, machines and procedures the area really needs, written so they can be observed and signed off: "torque check, station 4", not "quality". Put safety-critical and customer-critical tasks first. - 2
List the people and their shift
Everyone who works in the area, temporary staff included. The shift column is what lets the Excel count cover per shift. - 3
Rate each person against the standard
Use the written standard for the task (the job breakdown or SOP). The trainer or team leader confirms the level by watching the person do the job, not by self-rating alone. Write your own one-line definition for each level. - 4
Set the cover you need
For each task, how many people should be able to do it alone, overall and per shift. One more qualified person than the task needs at one time is a common starting rule, so one absence does not stop it. - 5
Read coverage, gaps and status
Coverage counts people at 3 or 4. A task with one person is a single point of failure even if the gap looks small. Then check the cover by shift sheet: three qualified people all on days still leaves nights with none. - 6
Write the training plan
Who will reach which level on which task, by when, and who trains them (a level 4). Work the biggest gaps first, then versatility. The Excel tells you whether each row closes a gap on that person's shift. - 7
Keep it live
Change a level only after sign-off, and the plan flags rows signed off but not yet updated on the matrix. Review it on a fixed cycle, monthly for example, and whenever someone joins or leaves.
The scale
What each level means
Levels 1 to 4 line up with the ILUO letters common in lean plants. That convention is common practice, not a standard, so write your own definition for each level and keep it with the matrix.
| Level | Means | ILUO letter | Harvey ball | Counts as cover? |
|---|---|---|---|---|
| 0 | Not trained | None | Empty | No |
| 1 | In training: knows the steps, works only under supervision | I | A quarter | No |
| 2 | Can do the task with help or checks | L | Half | No |
| 3 | Can do the task alone, to standard | U | Three quarters | Yes |
| 4 | Can do it alone and train others | O | Full | Yes, and as a trainer |
0
- Means
- Not trained
- ILUO letter
- None
- Harvey ball
- Empty
- Counts as cover?
- No
1
- Means
- In training: knows the steps, works only under supervision
- ILUO letter
- I
- Harvey ball
- A quarter
- Counts as cover?
- No
2
- Means
- Can do the task with help or checks
- ILUO letter
- L
- Harvey ball
- Half
- Counts as cover?
- No
3
- Means
- Can do the task alone, to standard
- ILUO letter
- U
- Harvey ball
- Three quarters
- Counts as cover?
- Yes
4
- Means
- Can do it alone and train others
- ILUO letter
- O
- Harvey ball
- Full
- Counts as cover?
- Yes, and as a trainer
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): an assembly cell with ten people on two shifts, five on days and five on lates, and eight tasks. Cover needed is 4 people per task overall and 2 per shift, example values the site sets. The Excel Example sheets give the same numbers.
The example's cover by shift: where the gap really is
- 0 Not trained
- 1 In training, supervised
- 2 Can do it with help
- 3 Can do it alone, to standard
- 4 Can train others
Now: people at level 3 or 4, per shift
- Torque check, days1 persongap of 1
- Torque check, lates1 persongap of 1
- Fixture changeover, days3 peoplecovered
- Fixture changeover, latesnobodygap of 2
After the plan's sign-offs
- Torque check, days3 peoplecovered
- Torque check, lates2 peoplecovered
- Fixture changeover, lates2 peoplecovered
The skill scale runs from 0, not trained, to 4, can train others, and only levels 3 and 4 count as cover. Cover needed is 2 per shift. Torque check has 1 person on days and 1 on lates; fixture changeover has 3 on days and none on lates, a gap of 4 by shift where the overall count showed 3. After the plan's sign-offs: torque check 3 on days and 2 on lates, fixture changeover 2 on lates, and no gap.
- Six tasks have 7 to 10 people at level 3 or 4. Torque check has 2 (Ana on days, Fay on lates) and fixture changeover has 3, so the gap row shows 2 and 1: a total gap of 3 sign-offs.
- The cover by shift sheet shows a gap of 4, not 3. Each shift has exactly one person for the torque check, and all three people qualified on fixture changeover work days, so the late shift has none.
- Ana is the only level 4 on both short tasks, so she is the trainer on five of the seven plan rows: Dev and Ben (days) and Gus (lates) to level 3 on the torque check, Fay and Hana (lates) to level 3 on fixture changeover.
- Two more rows, Eli on final inspection and Ivan on leak test, build versatility but close no gap; Ivan's sign-off is 5 days past its target date and the plan flags it.
Five of the seven rows close a gap. Once they are signed off, torque check goes from 1 to 3 people on days and 1 to 2 on lates, fixture changeover from 0 to 2 on lates, and the gap left after the plan is 0 on every task and shift.
Common mistakes
Listing job titles or vague skills
"Quality" cannot be observed or signed off. "First-piece inspection on press 2" can.
Self-rating with no standard
Without a written definition per level and a sign-off by someone who watched, levels drift upwards and the matrix stops meaning anything.
Counting everyone as cover
People at level 1 or 2 cannot run the task alone. Count only levels 3 and 4.
Looking only at the total
Four qualified people sounds safe until you see they all work days. Count cover per shift.
Training whoever is free
Plan training against the gaps first. Rows that close no gap can wait, however keen the person is.
One trainer for everything
If one person is the only level 4 on the short tasks, the plan depends on them too. Get a second person to level 4 on those tasks.
Building it once for an audit
An out-of-date matrix is worse than none, because people trust it when they plan cover.
From this worksheet to a running system
LeanSuite keeps this as a live skills matrix: people qualify through training and digital sign-offs.
- Each job profile (team) lists its required skills, levels and qualifications, such as required hours.
- Sign-offs and passed courses raise skill levels, and the Job Cover Matrix shows who is qualified where.
- Gap planning shows who needs which skills across the facility. Assign training straight from the gap view.
In LeanSuite
Use this as a Lean Studio board
The same method is one of the 30 ready-made board templates in Lean Studio, LeanSuite's whiteboard: Skills Matrix, visualize team skill coverage and training gaps across key operations using I/L/U/O levels.
- Start from the Skills Matrix template: a Table widget with people down the side and operations across the top.
- Enter each person's level per operation as I, L, U or O, and colour the cell by level.
- Add a sticky per training gap with the plan and the date, and update the level when the person signs off.
Worked example · sample data
The sample matrix covers three people across five operations. A. Kaur can teach setup, works alone on weld and pack, is learning inspection and is in training on the forklift. J. Lind can teach weld and forklift, works alone on inspect and pack, and is learning setup. M. Osei can teach inspection, works alone on weld, is learning pack, is in training on setup and has no forklift level at all, shown in red. The qualified row counts U or O per column: one for setup, three for weld, two each for inspect and pack, one for forklift. Setup and forklift each rest on one person. The team leader booked J. Lind's setup sign-off with A. Kaur as trainer first, since a setter off sick stops the shift, and put M. Osei on the next forklift course.
Three people against five operations with I, L, U or O in the cells, one empty red cell where M. Osei has no forklift skill, and a qualified count per operation. Sample data.
Open this board in LeanSuite
Skills Matrix is one of the 30 ready-made boards in Lean Studio, LeanSuite's whiteboard. Try LeanSuite in your browser, or run it on your own lines for 90 days.
What Lean Studio isHow to run a Skills Matrix session
- 1List the operations for the area across the top and the people down the side. Agree in writing what each level means: I in training, L learning, U works alone, O can teach.
- 2Fill it in with the team leader and each person, not from records alone. A person often knows they are no longer current on an operation.
- 3Read the columns: any operation with fewer than two people at U or O is a single point of failure.
- 4Plan training against the gaps: who, on what, with which trainer, by when. Put it on a sticky beside the matrix.
- 5Update levels only when a trainer signs off, and review the matrix monthly at the tier 2 meeting and whenever someone joins or leaves.
Common mistakes
- Levels from memory, or from a course certificate years old.
- No written definition of the levels, so O means something different on each shift.
- Reading only the rows. The columns show the risk.
- A matrix nobody updates, so the cover plan on a bad Monday is wrong.
- Training the willing instead of training the gaps.
Where it goes next in LeanSuite
- Competency Management keeps the matrix live: job profiles set the required skills and levels, trainers sign off on a tablet, levels rise from courses and sign-offs, and the Job Cover Matrix shows single points of failure and who to cross-train first. Competency Management
- The training that closes a gap is assigned from the gap view, and passing a course linked to a skill raises the level on the matrix automatically. Trainings (LMS)
- The Kaizen team builder suggests people by skill and workload, and a shadow can be added to a project to build a skill. Kaizen & Projects
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
LeanSuite gives you a live skills matrix: proficiency levels update as employees complete tasks and training in LeanSuite, and you can bulk-assign training to close the gaps it shows.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- Closing Plant-Wide Skill Gaps in 90 Days: A Practical Framework
- Why One Employee Absence Can Shut Down Production Lines
- TWI Job Instruction: The Training Method Behind Standard Work
- Model area: a 90-day plan for each pillar, then expansion
- Training matrix template with expiry dates
- Cross-training plan template
- Competency assessment form, the evidence behind one person's ratings
- OJT checklist, the training record that backs a level 3 sign-off
- One point lesson template, for the short lessons a training plan needs
- Best skills matrix software: 7 tools compared for plants
FAQ
Skills matrix template: common questions
The names are often used for the same grid. Where they differ, a training matrix records which courses each person has completed, while a skills matrix records how well each person can actually do each task. This template records ability, and its training plan links each gap to the training that closes it.
0 is not trained and each level adds a quarter of the circle: 1 in training under supervision, 2 can do it with help, 3 can do it alone to standard, 4 can also train others. Levels 1 to 4 match the ILUO letters many lean plants use. Only levels 3 and 4 count as cover.
Enough that one absence, holiday or resignation does not stop the work on any shift. A common starting rule is one more qualified person than the task needs at one time, per shift. Set your own number for each task and let the gap rows show where you fall short.
A skills matrix is organized around people and shows each person's level on each task. A job cover matrix is organized around jobs and shows how many people can cover each one. The Cover by shift sheet in this Excel is the job cover view of the same ratings.
The competency assessment form is the one-person check behind a single rating. The cross-training plan schedules one person's rotation through tasks. The skills matrix is the team view that shows where those checks and rotations are needed most.
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- 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.
- 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.
- 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.
- 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.
- 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.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- 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.
- 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.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- 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.
- 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.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- 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.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log 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.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- 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.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- 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.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- 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.
- Fire extinguisher inspection checklist and logThe 8 monthly checks for each portable extinguisher, plus a log with the hydro test interval from OSHA Table L-1, annual and 6-year due dates and open issues.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- 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.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- 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.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- Energy loss matrix templateSeven types of energy loss by six energy sources with a cost in each cell, an action plan and an idle-period shutdown checklist.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Chemical inventory and SDS register templateA register of every chemical on site with its hazard class, safety data sheet and label, and a check that incompatible products are kept apart.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- 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.
- Vehicle inspection checklist53 checks for a truck, tractor or trailer, each tied to the federal rule it comes from, with a defect log.
- Pre-trip inspection checklistA driver's 42-check walk-round in order, with the driver vehicle inspection report for the end of the day.
- 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.
- Management of change formA change request and review form for a plant: what changes, the hazard review, approvals, pre-startup review, training and close-out.
- Silica exposure control plan templateA written silica plan for general industry: tasks, controls and housekeeping, plus monitoring, medical surveillance, training and a 31-check plan audit.
- OKR template for manufacturingObjectives with three or four key results each, scored 0 to 1.0 from baseline and target every month, cascaded to facility, department and person with an Other bucket for work that serves no objective.
- Goal cascade and alignment templateA one-page cascade tree from company to person with the catchball reply on every card, and an initiatives list that shows how much work serves a goal and how much sits in Other.
- Monthly business review template (operations review agenda)A 90-minute operations review in nine timed blocks: who speaks when, the KPIs each block reviews with red or green, a prep checklist for every presenter and a log of decisions and actions.
- Rolling action item list (RAIL) templateA single running list of actions kept from meeting to meeting, with a weekly review sheet and age counts.
- Goods received note templateA one-page goods received note and an Excel register with accepted to date, still to come and an invoice check for each PO line.
- Lessons learned templateA one-page lessons log, a 45 minute session guide and an Excel register that shows which actions are done, open or overdue.
- Packing list templateA one-page packing list with a pack checklist, and an Excel file that works out volume, shipped to date and back order.
- Meeting minutes templateA one-page minutes form and an Excel log of decisions and actions with owners, due dates and status.
- Purchase order templateA one-page purchase order and an Excel version that adds up the lines, checks the approval limit and tracks what is still to come.
- Action plan templateA one-page action plan and an Excel tracker with percent done, status and a weekly timeline.
- Part submission warrant (PSW) templateA PSW working form plus twelve checks before anyone signs, and an Excel that works out whether the warrant is ready.
- Ballooned drawing and dimensional results templateA ballooning guide and a results sheet for six parts per characteristic, with OK, NEAR LIMIT or NOT OK worked out for each row.
- Attribute agreement analysis templateA 30-part, three-appraiser study sheet for pass or fail decisions, with kappa, effectiveness, miss rate and false alarm rate in Excel.
- DVP&R template (design verification plan and report)A design verification plan and report on one sheet: tests, criteria, owners and dates, with status worked out as of a date.
- Special characteristics matrix templateOne row per special characteristic, followed from drawing to PFMEA, control plan, gauge study and capability, with the first gap named.
- Maintenance request form templateA one-page request form and an Excel log that times each answer against a priority target.
- Maintenance log templateA maintenance log page and an Excel log that totals cost, downtime and planned work and flags repeat breakdowns.
- Preventive maintenance schedule templateA PM schedule with next due dates and status, and an Excel calendar of the jobs and hours in each month.
- Machine setup sheet templateA setup sheet with limits, a first piece check and setup minutes, and an Excel log of setups against a standard.
- Fire drill report templateA report for each fire or mock drill: a timeline from the alarm, the head count, an observer checklist, actions and a yearly log.
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