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Standard work audit checklist
A standard work audit is a periodic check that the written standard for a job still matches what happens at the station, and that the standard is still the best known way to do it. It looks at more than whether the operator is doing it right: whether the posted document is current, whether the sequence and the key points are followed, whether cycle times still fit the standard and takt, whether the operator was trained on this revision, and whether the tools and material let the job be done as written. Each gap then needs a cause, because an operator who drifted from a good standard and a standard that no longer fits the job look the same on the floor and call for opposite fixes. Page 1 of the PDF has 24 checks in six groups, each answered Yes, No or N/A with what you saw. Page 2 has ten timed cycles against the standard and its agreed range, the score by group, the four causes of a gap and a table for each gap's cause and action. The Excel version scores each group and the audit as Yes ÷ (Yes + No), checks the cycles against the range, flags a No without a cause, and has an audit log with a trend chart.
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Fields for station, standard and revision, date, auditor, operator and shift, audit type boxes, and 24 checks in six dark-headed groups from documentation to quality and safety, each with Y, N and N/A to circle and space for what you saw.24 checks in six groupsYes, No, N/ATen timed cyclesAgreed range checkScore by groupFour causes of a gapActions with ownersAudit log and trend
When to use it
When to use a standard work audit checklist
- On a schedule for every job with written standard work, more often for high-risk or high-variation jobs.
- After a change to the job, the product, the takt or the equipment, to check the standard was updated and the operators retrained.
- When quality or output on a job drifts and you want to know whether the standard is followed or out of date.
- As the periodic outside check that sits on top of the daily checks in leader standard work.
How to fill it in
- 1
Take the current controlled copy
Bring the standard as it should be, then compare the copy posted at the station with it. A different revision is the first finding.
- 2
Watch before you answer
Watch at least three full cycles before answering the sequence checks. Stand where you can see the hands and the path without getting in the way.
- 3
Time ten cycles
Time each cycle from the same start point and write it on page 2. Mark any cycle outside the agreed range of the standard and note why: waiting, searching, rework.
- 4
Ask, then check the records
Ask the operator to say each key point and why it matters, then check the skills matrix and the training record for this revision.
- 5
Give every No a cause
Not followed, standard out of date, cannot be followed, or not trained. The cause decides the action: coaching, an updated standard, a fixed condition or training.
- 6
Agree the actions and look at the trend
Give each action an owner and a date before you leave, and compare with the last few audits of the job. A No that keeps coming back points to the system.
What's on the checklist
The 24 checks on the standard work audit checklist
Six groups, from the document at the station to quality and safety. On the sheet each check is answered Yes, No or N/A with what you saw; every No gets one of four causes and an action on page 2.
Documentation
Is the posted standard the one in use?
- 1The standard for this job is posted at the station and can be read from where the work is done
- 2Its revision matches the current controlled copy
- 3It covers the part or model running now
- 4Takt time and the standard cycle time on it are current
- 5Key points and their reasons are marked for quality, safety and knack
Sequence
Watch at least three full cycles
- 6The operator does the work elements in the written order
- 7No element is skipped and none is added
- 8Each key point is done as written
- 9The operator walks the path drawn on the standard work chart
- 10Standard WIP is at the stated quantity and in its marked places
Time
From the cycles timed on page 2
- 11Observed cycle times fall within the agreed range of the standard
- 12No cycle includes waiting, searching or rework
- 13The standard cycle time is still at or below takt
Training
Check the records, then ask the operator
- 14The operator is shown as qualified for this job on the skills matrix
- 15Training on the current revision is recorded
- 16The operator can say each key point and why it matters
- 17The operator knows what to do when something goes wrong: stop, call, andon
Tools, equipment and material
What the standard names, where it says
- 18Tools, gauges and fixtures are the ones the standard names, in their places
- 19Gauges are inside their calibration date
- 20Material is presented where and how the standard shows
- 21Machine settings match the values on the standard
Quality and safety
As written on the standard
- 22In-process checks are done at the stated frequency and recorded
- 23The PPE the standard lists is worn
- 24Safety key points are followed: guards, lockout, lifting
A filled-in example
Illustrative, not a benchmarkAn audit of final assembly station 3 against standard SW-3, revision C (illustrative), the same as the Excel worked example.
Five No answers, three causes, three fixes
- Cause B: update the standard
Check 4: the sheet still shows a 62 s takt after the change to 60 s
- Cause C: fix the condition
Checks 11 and 12: cycle 5 took 66 s, over the 63.8 s limit; the torque gauge had been borrowed
- Cause D: train on revision C
Checks 8 and 15: bolts torqued 1-2-3-4, not the cross pattern; training record shows revision B
- 18 Yes, 5 No and 1 N/A (no machine settings at a manual bench): 18 ÷ 23 = 78%.
- Ten cycles timed against a standard of 58 s with a ±10% range, 52.2 to 63.8 s. The average was 59.5 s, but cycle 5 took 66 s because the torque gauge had been borrowed by station 4. Checks 11 and 12 are No, cause C: fix the condition.
- The posted sheet still showed a takt of 62 s after the schedule change to 60 s. Check 4 is No, cause B: update the standard.
- The operator torqued the bolts 1-2-3-4 instead of the cross pattern added in revision C, and the training record shows revision B. Checks 8 and 15 are No, cause D: train on revision C with Job Instruction.
Five No answers come down to three gaps with three different fixes: update the sheet, give the gauge a place it returns to, and retrain on the current revision. Telling the operator to follow the standard would have fixed none of them.
Common mistakes
Auditing only the operator
Half of the gaps an audit finds are in the standard, the training or the conditions. Check the document, the records and the tools as well as the person.
Answering from one cycle
One cycle can look perfect or terrible by chance. Watch several and time ten before you answer the sequence and time checks.
Retraining someone into a worse method
When the operator's way is better, the finding is an out-of-date standard. Update it, then train everyone on the new version.
Always the same auditor on the same shift
Rotate auditors and shifts. Someone who walks the line every day stops seeing the shortcuts that have become normal.
Download the template
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Run this template in LeanSuite
In LeanSuite a standard work audit is a checklist built in Lean Creator or drafted by the AI, scheduled in Daily Standard Work to a person, a role or a machine with a repeat rule, and completed on a phone or tablet with photo evidence, and every finding becomes a tracked action.
See it in a 45-minute demoIn the lean glossary
Guides
- Auditing Standard Work: Verification and Compliance Checks
- Leader Standard Work: What Manufacturing Leaders Should Do Daily
- Standard Work in Manufacturing: A Complete Guide
- Layered Process Audit: The Benefits and Implementation Guide
- Best layered process audit software: 7 tools compared
- Best standardized work software: 7 tools compared
Put it on the wall
FAQ
Standard work audit checklist: common questions
Whether the posted standard is current, whether the operator follows the sequence and key points, whether cycle times still fit the standard and takt, whether the operator was trained on this revision, and whether the tools and material let the job be done as written.
Leader standard work is the daily check by the team leader or supervisor, close to the work. A standard work audit is periodic and often done by someone from outside the area, so it catches the slow drift that daily familiarity misses. The two work together.
There is no fixed rule. Audit high-risk and high-variation jobs more often than stable ones, rotate across shifts and auditors, and audit again after any change to the job, the product or the takt.
Find out why first. If the standard is right, coach the operator the same day and retrain with Job Instruction. If the operator's way is better or the job changed, update the standard. If something stops the operator working to it, fix that condition.
Each check is Yes, No or N/A, and the score is Yes ÷ (Yes + No), by group and overall, with N/A left out. The score shows the trend; the No answers and their causes are what you act on.
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- 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.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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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.