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SQF internal audit checklist for food manufacturing
An SQF internal audit is the site's own check that its food safety system and its good manufacturing practices work as the SQF Food Safety Code for Manufacturing asks. Trained staff do it before the certification body comes. More broadly, a food safety audit is any planned, recorded check of a food plant against a standard: by the plant itself, by a customer, by a certification body or by a regulator. This checklist has 54 questions in plain words, in the two parts the Code is built from. The system elements cover management commitment and culture, documents, suppliers, the HACCP food safety plan, verification and corrective action, traceability and recall, food defense and fraud, allergens and training. The GMP module covers the production floor. Each group names its BRCGS Issue 9 section and FSSC 22000 counterpart, so a site certified to one scheme, or moving between them, can use the same list. The Excel version grades every question Conforms, Minor, Major, Critical or N/A, lists the findings with owners and due dates, scores each group and part, and plans the year's audits. SQFI published Edition 10 in March 2026 and expects audits to it to start on 2 January 2027, subject to GFSI benchmarking; until then sites are audited to Edition 9, so check each question against the edition your audit is to. The checklist supports internal audits beside your own food safety system. It does not quote the Code, and a good score does not certify a site or make it compliant.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Site, edition, date and auditor fields, the five grades, and the first questions on management commitment, documents and suppliers with their BRCGS and FSSC 22000 counterpart, grade circles and space for evidence.54 questions in 16 groupsSystem elements and GMP moduleBRCGS and FSSC 22000 crosswalkFive grades with days to closeEvidence, finding, owner, due dateScore by group and partFindings listYearly audit planWorked example (granola bar plant)
When to use it
When to use an SQF audit checklist
- For the internal audits the SQF Code asks for, on a plan that covers every requirement through the year.
- As a gap check before a certification, recertification or customer audit, with time left to close the findings.
- When moving from Edition 9 to Edition 10, or between SQF, BRCGS and FSSC 22000, to see what each group maps to.
- After a recall, a customer complaint trend or a major finding, to audit the groups it touched again.
- Not as the monthly floor walk: the food GMP inspection checklist is shorter and built for that.
How to fill it in
- 1
Plan the year
List every group on the plan sheet and say how many times a year it is audited. The example audits higher-risk groups (HACCP, verification, allergens, cleaning, personnel practices, foreign matter) twice and the rest once. Check the minimum your edition of the Code sets.
- 2
Choose auditors who are not auditing their own work
Trained in internal auditing and in the Code, from another area. A supervisor from line 1 audits line 2, and QA's own records are audited by someone outside QA.
- 3
Start on the floor, then go to the records
Watch a changeover, a CCP check, a hand wash. Then pull the records for what you saw and sample others: 10 changeovers, 8 operators' training files, the last three corrective actions.
- 4
Grade each question with the evidence
Conforms, Minor, Major, Critical or N/A. Write what you saw for a conformance too, not only for findings: "records for 10 of 10 sampled CCP checks signed and reviewed" is evidence; a tick is not.
- 5
Give every finding an owner and a date
The example settings close a Major in 14 days and a Minor in 30, and a Critical means stopping and holding product the same day. Set your own in the Excel settings.
- 6
Close with a check and report the trend
A finding closes when someone has checked the fix worked. Take the score by group, the open findings and any repeat findings to management review.
What is a food safety audit?
Four kinds of food safety audit
The same plant can see all four in a year. This checklist is for the first one, and gets you ready for the other three.
| Kind | Who does it | Against what | What it gives you |
|---|---|---|---|
| Internal audit (first party) | Your own trained staff, not auditing their own area | Your food safety system and the scheme you are certified to | Findings you fix before anyone else finds them. SQF, BRCGS and FSSC 22000 all ask for internal audits. |
| Customer audit (second party) | A customer's auditor, or your team at a supplier | The customer's own requirements, often on top of a GFSI-recognised scheme | Approval to supply, or approval of your supplier |
| Certification audit (third party) | A certification body licensed for the scheme | SQF, BRCGS, FSSC 22000 or another scheme GFSI recognises | A certificate that many retailers and brand owners ask for |
| Regulatory inspection | FDA, USDA FSIS or state inspectors | The law, such as 21 CFR 117 or 9 CFR 416 and 417 | Enforcement, not a certificate. It can come without notice. |
Internal audit (first party)
- Who does it
- Your own trained staff, not auditing their own area
- Against what
- Your food safety system and the scheme you are certified to
- What it gives you
- Findings you fix before anyone else finds them. SQF, BRCGS and FSSC 22000 all ask for internal audits.
Customer audit (second party)
- Who does it
- A customer's auditor, or your team at a supplier
- Against what
- The customer's own requirements, often on top of a GFSI-recognised scheme
- What it gives you
- Approval to supply, or approval of your supplier
Certification audit (third party)
- Who does it
- A certification body licensed for the scheme
- Against what
- SQF, BRCGS, FSSC 22000 or another scheme GFSI recognises
- What it gives you
- A certificate that many retailers and brand owners ask for
Regulatory inspection
- Who does it
- FDA, USDA FSIS or state inspectors
- Against what
- The law, such as 21 CFR 117 or 9 CFR 416 and 417
- What it gives you
- Enforcement, not a certificate. It can come without notice.
What's on the checklist
The 54 questions on the SQF internal audit checklist
Nine groups of system elements, then seven for the GMP module. Under each group is its BRCGS Issue 9 section and FSSC 22000 counterpart, named, not quoted. On the sheet each question is graded Conforms, Minor, Major, Critical or N/A with the evidence seen.
Management commitment and food safety culture
BRCGS Issue 9: section 1. FSSC 22000: ISO 22000 clauses 5 and 9.3, plus the FSSC culture requirement
- 1Is there a signed food safety policy, and can operators on the floor say in their own words what it asks of them?
- 2Are the SQF practitioner and a substitute named, and is there evidence they meet the training the Code asks for, including HACCP training?
- 3Is there a written plan for food safety culture with measures, and are the results reviewed and acted on?
- 4Did management review the food safety system at the planned interval, with records of inputs, decisions and actions?
- 5Are customer complaints logged, investigated for cause, trended and closed with corrective action?
Documents and records
BRCGS Issue 9: section 3. FSSC 22000: ISO 22000 clause 7.5
- 6Is the food safety manual or document register current, with every procedure in use at its latest approved version?
- 7Are changes to documents approved before use, and are obsolete copies removed from the floor?
- 8Are records legible, complete, signed where required and kept for the period the site has set, and can they be found within minutes?
Specifications, suppliers and contract services
BRCGS Issue 9: sections 3 and 5. FSSC 22000: ISO 22000 clause 7.1.6
- 9Are there current specifications for every raw material, ingredient and packaging material, including allergen status?
- 10Is supplier approval based on risk, and are supplier certificates, audits or test results current for every approved supplier?
- 11Are contract service providers (cleaning, pest control, laboratories, maintenance) approved and their work checked?
- 12Are finished product specifications and customer requirements current and available where they are needed?
Food safety plan (HACCP)
BRCGS Issue 9: section 2. FSSC 22000: ISO 22000 clause 8.5
- 13Does the HACCP team cover the needed skills, and was the flow diagram checked on the floor against how the line runs today?
- 14Does the hazard analysis cover biological, chemical (including allergens), physical and radiological hazards for every step?
- 15Is there evidence that each critical limit was validated, and were controls revalidated after a change to the product or process?
- 16Is each CCP monitored at the stated frequency by a trained person, with records signed and reviewed?
- 17When a CCP was out of limit, was the product held, its fate decided and recorded, and the cause corrected?
Verification, internal audits and corrective action
BRCGS Issue 9: sections 3, 4 and 6. FSSC 22000: ISO 22000 clauses 8.7, 8.8, 9.2 and 10, plus the FSSC environmental monitoring requirement
- 18Is there a verification schedule for monitoring, records review and testing, and was it followed this period?
- 19Do internal audits cover every requirement of the Code on a set schedule, done by trained auditors who do not audit their own work?
- 20Do corrective actions record the cause, the action, who closed it and the check that it worked, within the due date?
- 21Is there an environmental monitoring program based on risk, with zones, sites, frequency and limits, and are the results trended?
- 22Are monitoring and measuring devices (thermometers, scales, detectors) calibrated or checked on schedule, with records?
- 23Were the findings of the last internal and external audits closed, and did the same finding come back?
Product identification, traceability, withdrawal and recall
BRCGS Issue 9: section 3. FSSC 22000: ISO 22000 clauses 8.3 and 8.9.5
- 24Are raw materials, work in progress, rework and finished product identified with a lot code all the way through?
- 25Can the site trace one finished lot back to its suppliers' lots and forward to its customers, with quantities that reconcile?
- 26Is the recall and withdrawal plan tested on the schedule the Code sets, with the result and the time taken reviewed?
Food defense and food fraud
BRCGS Issue 9: sections 4 and 5. FSSC 22000: the FSSC food defense and food fraud requirements
- 27Is there a food defense threat assessment and plan, with access controls that work on the floor?
- 28Is there a food fraud vulnerability assessment covering ingredients and packaging, with the controls it calls for in place?
Allergen management
BRCGS Issue 9: section 5. FSSC 22000: the FSSC allergen management requirement
- 29Is there an allergen risk assessment and a list of every allergen on site, by ingredient, line and product?
- 30Are allergen ingredients stored and handled apart, and is the changeover clean checked and recorded before the next run?
- 31Are labels and packaging checked against the product at line start, at every changeover and when a new label stock is loaded?
Training
BRCGS Issue 9: section 7. FSSC 22000: ISO 22000 clause 7.2
- 32Is there a training plan that covers GMP, hygiene, allergens, cleaning and each CCP task, including for temporary staff?
- 33Do training records exist for a sample of operators on the floor, and is there a check that the training worked?
Premises and equipment
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 34Are floors, walls, ceilings, doors and lighting in repair, cleanable and protected where product is exposed?
- 35Is equipment made of food-grade materials, in good condition and designed so it can be cleaned?
- 36Are temporary repairs controlled and removed on time, and is equipment cleared for hygiene after maintenance?
- 37Is the glass and brittle plastic register current, with the items checked on schedule and breakages handled?
Cleaning and sanitation
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 38Are written cleaning procedures (SSOPs) in place for each area and machine, and are they followed as written?
- 39Are pre-op inspections and cleaning verification (visual, ATP, microbiological) recorded, with failures recleaned before release?
- 40Are cleaning chemicals approved for food plants, labelled, stored apart from food and issued under control?
Pest prevention
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 41Is there a pest prevention program with a device map, a qualified provider and reports reviewed by the site?
- 42Is the building proofed against pests, and was activity found on the walk or in the reports followed up?
Personnel hygiene and practices
GMP module. BRCGS Issue 9: section 7. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 43Do people wash and sanitize their hands at the right times, at sinks that are stocked and working?
- 44Are protective clothing, hair and beard covers, jewelry and personal items handled as the site rules say?
- 45Do staff know they must report illness, and is there a record of who was excluded or moved?
- 46Do visitors and contractors follow the same hygiene rules, with a sign-in and a briefing?
Water, ice and air
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 47Is water used in product, for cleaning and for ice tested on schedule, with results that meet the site's limits?
- 48Are compressed air and other gases that touch product filtered and checked on schedule?
Receiving, storage and transport
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 49Are incoming loads checked for condition, temperature where it matters, and the right documents before they are accepted?
- 50Is stock stored off the floor, rotated, kept apart by type and at the right temperature?
- 51Are vehicles and containers checked for cleanliness, condition and temperature before loading?
Foreign matter, separation and waste
GMP module. BRCGS Issue 9: section 4. FSSC 22000: ISO 22000 clause 8.2 and ISO/TS 22002-1
- 52Are metal detectors, X-ray units, sieves or magnets checked at the stated frequency with test pieces, and do rejects go to a locked bin?
- 53Are raw and ready-to-eat, and allergen and allergen-free, kept apart by layout, flow or timing as the plan says?
- 54Is waste collected in marked containers, removed often enough and kept from attracting pests?
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): the full internal audit of a made-up granola bar plant with two lines, peanuts and almonds on line 2. The QA lead and the line 1 production supervisor audit over two days, and neither audits their own area.
The example audit, conforms by part
- System elementsLowest29 of 33
- GMP module18 of 20
- All questions graded47 of 53
Bar chart of the example internal audit at a granola bar plant: system elements 29 of 33 conform, 87.9 percent; GMP module 18 of 20 graded conform, 90.0 percent; all 47 of 53, 88.7 percent. 2 Major and 4 Minor findings, 1 N/A.
- 54 questions. 1 is N/A (no compressed air or gas touches product), so 53 are graded: 47 Conforms, 4 Minor, 2 Major and no Critical.
- Major: 2 of 10 sampled line 2 changeovers have no record that the allergen clean was checked before the next run, and 3 corrective actions from the last internal audit are past due, one with no cause recorded.
- Minor: the oat supplier's certificate ran out three weeks ago, 1 of 8 sampled operators has no allergen training record, tape on a line 1 conveyor guard is not on the temporary repair log, and one weekly glass check was missed.
- System elements: 29 of 33 conform (87.9%). GMP module: 18 of 20 graded conform (90.0%).
- The year's plan: 16 groups, 6 audited twice and 10 once, 22 group audits in all.
Score 47 ÷ 53 = 88.7%. Both Majors are due in 14 days and the four Minors in 30 (this template's example settings). The allergen changeover record goes first because it is closest to the product, and the late corrective actions show the plant's own loop is not closing, which is the next audit's first question.
Common mistakes
Auditing the manual, not the floor
A procedure that exists is not a procedure that is followed. Start every group on the floor, then check the records against what you saw.
Auditing your own area
QA auditing its own records, or a supervisor auditing their own line, misses what they no longer see. Swap auditors between areas.
Ticks with no evidence
"Yes" with nothing written cannot be checked later, by you or by the certification auditor. Write the sample and what you found for every question.
Closing findings on a promise
A finding closed because the owner said it was fixed comes back at the certification audit. Close it when someone has seen the fix work, and find the cause for every Major.
Using an old edition's list
Checklists copied from Edition 8 or 9 drift from what the auditor will use. Check every question against the edition your next audit is to, and add your own site's requirements.
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Guides
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- LeanSuite for food and beverage plants
FAQ
SQF internal audit checklist for food manufacturing: common questions
A planned, recorded check of a food plant against a standard, with evidence for each finding. It can be internal (the plant's own staff), a customer's audit, a certification audit against a scheme such as SQF, BRCGS or FSSC 22000, or a regulatory inspection by FDA, USDA FSIS or the state. Internal audits find the gaps before the others do.
The SQF Code asks for internal audits on a planned schedule that covers the whole system; check the minimum interval in the edition you are certified to. This template's example plan audits every group at least once a year and higher-risk groups twice, with a monthly GMP floor walk on top.
All three are certification schemes that GFSI recognises. SQF is run by SQFI, part of FMI, and is common in North America; BRCGS started in the UK; FSSC 22000 is built on ISO 22000 plus the sector program for prerequisites (ISO/TS 22002-1 for manufacturing) and its own extra requirements. They cover much the same ground in different structures, which is why each group on this checklist names its counterpart in the other two.
SQF audits grade findings in those three levels: broadly, a lapse that does not threaten food safety on its own, one that could if left, and one where food safety is at risk now or records were falsified. The Code defines them and sets the time to close each; this template uses the same three words with its own example days so internal findings read the same way.
The one your next certification audit is to. SQFI published Edition 10 in March 2026 and expects audits to it to start on 2 January 2027, subject to GFSI benchmarking; audits before that date are to Edition 9. Check sqfi.com for the current dates.
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- 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.
- 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.
- 1-1-90 method worksheetOne page: score areas 1 to 5, write the pain point with a before and target number, check days 30, 60 and 90, and plan the next three areas.
- Leader standard work templateA team leader's daily, weekly and monthly routine with a box per day, follow-ups and a weekly review.
- Supervisor leader standard work templateA supervisor's daily, weekly and monthly routine with a box per day, an escalation log and a weekly review.
- Production manager leader standard work templateA production or value stream manager's routine by day, week and month, with an escalation log and a weekly review.
- Plant manager leader standard work templateA plant manager's short routine by day, week and month, with an escalation log and a weekly review.
- Autonomous maintenance (CILR) checklist20 clean, inspect, lubricate and retighten checks with a box per day, an abnormality log and sign-off.
- A3 problem solving templateThe standard seven-box A3 from background to follow-up, with a filled-in worked example. PDF and Excel.
- PDCA templateOne improvement cycle on one page: plan, do, check against the goal, then standardize or adjust. PDF and Excel.
- 5 Whys templateA problem statement, a why chain that can branch, evidence for every answer, root causes and countermeasures that are checked.
- 5W1H templateWho, what, when, where, why and how: a problem statement built from checked facts, and an action plan with nothing left open.
- Skills matrix templatePeople by tasks on a 0 to 4 scale, coverage and gaps per task and shift, and a training plan that closes them.
- Standard work sheet templateTakt time, each element's manual, machine and walk time on a time chart, key points and standard WIP.
- One point lesson (OPL) templateOne topic on one page: wrong way and right way pictures, checkable key points, the standard it belongs to and a sign-off record.
- SMED changeover worksheetChangeover steps with times, internal or external, what can move, ideas and before/after totals.
- Kaizen event charter templateProblem, goal, scope in and out, boundaries, metrics from baseline to target, team and roles, and sign-off before day one.
- RACI matrix template17 kaizen project tasks by 10 roles, with R, A, C, I drop-downs and a check for one accountable per task.
- Shift handover templateSafety, production against plan, holds, downtime events, materials and people, and the open actions the next shift takes over.
- Shift schedule packTen shift patterns defined exactly, each with a 28-day calendar, hours worked out from the cycle and a US 40-hour check, plus an Excel roster.
- Kanban card templateSix production and six withdrawal kanban cards to print and cut out, with loop sizing and a card register.
- Idea suggestion formA one-page idea form with the supervisor's answer and points, and an idea log that tracks days to answer.
- Just Do It (JDI) card templateSix Just Do It cards per sheet for quick fixes, with the rules for what counts and a log of every card.
- Quick kaizen templateOne page for a small improvement: before and after, the cause, the countermeasure, the results and whether the standard changed.
- Time study sheetTime each element over 10 cycles and work out the average, lowest repeatable and standard time. Excel does the sums.
- Spaghetti diagram templateSquared paper to trace every trip, a trip log that turns grid squares into feet, meters and walking time, and a before and after comparison.
- OEE tracking sheetOne row per shift for a week. The Excel version works out availability, performance, quality and OEE and charts the week.
- Near miss report formA two-page near miss report from the first report to closure, and an Excel log with status and days open.
- Safety observation card templateFour behavior-based safety cards per sheet, with safe and at-risk checks, the conversation and a tally sheet.
- Job safety analysis (JSA) templateJob steps, hazards, risk scored before and after the controls, the hierarchy of controls, PPE and sign-off.
- Risk assessment matrix template (5×5)A color-coded 5 × 5 severity and likelihood matrix, a scoring guide and a risk register.
- Incident investigation report templateFacts and a sourced timeline, causes at three levels, actions by the hierarchy of controls, a US recordkeeping screen and a closure check.
- Incident report templateThe first report, filled in the same shift: what happened, people, injury or damage, treatment, a US recordkeeping screen, actions and an Excel incident log.
- Toolbox talk templateA record of a short safety talk: topic, key points, questions raised, actions and an attendee sign-in sheet.
- Lockout/tagout (LOTO) procedure templateA machine-specific LOTO procedure: energy sources and isolation points, the steps from shutdown to restart, and the annual review.
- Preventive maintenance checklist templateA PM checklist per machine with readings and sign-off, and a PM schedule that works out the next due date.
- Equipment downtime log (MTTR and MTBF)A breakdown and downtime log, with MTTR, MTBF and downtime by machine and cause worked out in Excel.
- Environmental aspects and impacts registerAn ISO 14001-style register of aspects and impacts, with significance scoring, legal requirements, controls and owners.
- Manufacturing process instruction (MPI) templateOperation steps with parameters, tools, quality checks, safety and a photo each, plus revision history and approval.
- Engineering process instruction (EPI) templateScope, parameters and limits, equipment and materials, validation steps, acceptance criteria, change history and approvals.
- Training sign-off sheetAn attendance and sign-off record where each person signs they understood, with a competence check and an Excel log.
- Learning curve and ramp-up workbookBoth learning curve models side by side, a fit from your own observed hours, batch hours, the unit that reaches standard and a weekly ramp plan.
- Operator staffing calculatorTakt, work content, the operators a line needs, a check of your station plan and the roster with absence cover, from your own demand and element times.
- On-the-job training (OJT) checklistThe training record for one trainee on one job: the four TWI steps signed, every try judged, qualified when your rule is met, then tapering follow-up checks.
- New hire onboarding checklist (manufacturing)29 onboarding items from before day 1 to the 90-day review, with owners, dates and review notes.
- Competency assessment formThe one-person assessment behind a skills matrix rating: each task rated 0 to 4 from evidence, checked, with a training plan for every gap.
- Cross-training plan templateWho is learning which task, from and to which level, by when, and how many are qualified on each task.
- Absenteeism tracker templateA monthly attendance grid with codes, absence rate by person and team, and an optional Bradford factor.
- Engineering change request (ECR) formAn ECR form with the change, what it touches, risk and approvals, and an Excel log that tracks each change to done.
- Process flow diagram templateA squared sheet to draw the flow with a symbol key, and a step table that counts operations, moves, checks, waits and storage.
- Lubrication schedule templateEvery lube point with lubricant, method, amount, frequency and who, with next due dates and a monthly sign-off record.
- TPM tag logEvery abnormality tag with type, who fixes it, priority and dates, with days open and counts by type and week.
- Autonomous maintenance step auditCriteria for each of the seven autonomous maintenance steps, scored 0 to 2, with the step result and the decision to move on.
- Inventory cycle count sheetA blind count sheet with variance and tolerance, an ABC count schedule and record accuracy, worked out in Excel.
- Hour-by-hour production boardHourly plan against actual with running totals and the reason for each miss, plus a shift summary by reason.
- Cost savings trackerA savings log with hard and soft savings, payback and Finance's sign-off, plus a glide path against the year's target.
- CapEx request formA capital request with options, costs, benefits, payback and NPV, and the approval levels the amount needs.
- Standard cost variance workbookEight standard cost variances from your standards and actuals, favorable or unfavorable, proved against actual cost, with the questions to ask on the floor.
- Cost-benefit analysis templateUp to three options side by side with costs, hard and soft benefits, payback, NPV and the benefit-cost ratio.
- Cost of poor quality (COPQ) worksheetCost of quality by prevention, appraisal, internal and external failure, with COPQ as a share of sales.
- Receiving logA dock receiving log with quantities, damage, QC holds and putaway, plus a discrepancy report and dock-to-stock time.
- Warehouse safety inspection checklistThirty warehouse safety checks from aisles to fire exits, marked OK or Not OK, with an action for every finding.
- Pallet racking inspection checklistRack checks per aisle with a green, amber and red damage rating, and a damage log with repair dates.
- Material shortage logEvery part short with its need date, line impact, ETA and escalation, and counts by reason and supplier.
- Ergonomic risk assessment checklistScreen a task for 21 ergonomic risk factors, score how long each lasts, and rank tasks so the worst get controls first.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- 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.
- 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.
- 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.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
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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.