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Supplier corrective action request (SCAR) form
A supplier corrective action request (SCAR) is a formal request from a customer to a supplier to contain a problem with the parts or material the supplier delivered, find its root cause and fix it so it does not come back. In quality, a SCAR is the supplier version of a corrective action request (CAR): your quality team writes the problem and checks the answer, and the supplier does the investigation and the fix in its own process. This free SCAR template is a 4-page PDF. Page 1 is filled in by the customer: the supplier and part, where the problem was found, the problem against the requirement with evidence, the containment asked for, and the date each part of the response is due. Pages 2 and 3 are the supplier's answer in 8D-style sections, from the team and containment to the root cause of why it was made and why it was not caught, the corrective actions, proof they work and closure, followed by the customer's verification and sign-off. Page 4 is the same form filled in for zinc plating that came in too thin. For a problem in your own plant, use the corrective action request form instead.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for the SCAR number, supplier, part and quantities, tick boxes for where it was found and repeat problems, a large box for the problem description, the containment requested, and a table of response due dates.Supplier and part detailsProblem with evidenceContainment requestedResponse due datesD1 to D8 supplier responseOccurrence and escape root causeCustomer verification and closureFilled-in example
When to use it
When to use a SCAR
- When parts from a supplier fail a requirement at receiving, in your process or at your customer, and you need the cause found, not only the parts replaced.
- For a repeat problem from the same supplier, or one serious enough to need a formal root cause: safety, fit and function, or a large share of a lot.
- When you need the supplier to sort stock at their site, in transit and at yours by a set date.
- To keep a record of supplier problems and response times for supplier reviews and the supplier scorecard.
- Not for every reject: a one-off with an obvious cause can go back with a note on the return. Keep SCARs for problems that need the supplier to change something.
How to fill it in
- 1
Describe the problem with evidence
The requirement with its drawing, revision and limit, what was found against it, how many out of how many checked, and how it was found. Attach the readings, photos, sample parts and your NCR number. - 2
Ask for containment by a date
Tick what you need: sorting at their site, in transit or at yours, replacement parts, and the next shipments marked as checked. Ask which lot is the first known good one. - 3
Set the response dates
A date for containment, one for the root cause and planned actions, and one for actions done and verified. Use the dates in your supplier quality manual or purchase terms. - 4
The supplier investigates
Team, problem in their words, containment with quantities sorted and found bad, and the root cause of both the occurrence and the escape, each confirmed with data. - 5
The supplier fixes and proves it
One corrective action for each confirmed cause, with an owner and a date, evidence that it works, and the PFMEA, control plan, instructions and similar lines updated. - 6
Verify and close
Check the next lots at receiving or audit the supplier, accept the response or send it back, and close only when the problem has not come back.
The SCAR process
The SCAR process and its response clock
Each stage has its own due date, so a late root cause shows up at day 10 instead of at the end. The days shown are the ones in the worked example below and are illustrative: your supplier quality manual or purchase terms set the real ones.
- Day 0Issue the SCARProblem against the requirement, evidence, containment asked for, and a due date for each stage.
- By day 2ContainmentEvery suspect lot sorted, at the supplier, in transit and at your site. The first good lot named.
- By day 10Root cause and planWhy it was made and why it was not caught, each confirmed with data, and an action for each.
- By day 30Actions doneEvidence each action works. PFMEA, control plan, instructions and similar lines updated.
- Next lotsVerify and closeCheck the next lots at receiving. Close when the problem has not come back, or send it back.
SCAR vs CAR vs 8D
SCAR vs CAR vs 8D vs CAPA: which document does which job
These five get mixed up because they share steps. The difference is who owns the cause and what the document is for. A serious NCR on bought-in parts opens a SCAR; the supplier often answers it as an 8D; and the SCAR is tracked in your CAPA log with your own corrective actions.
| Document | What it is | Who does the work | Use it when |
|---|---|---|---|
| SCAR | A corrective action request sent to a supplier about parts, material or a service they provided. The customer writes the problem and the due dates and verifies the answer. | The supplier finds and fixes the cause in its process. Your supplier quality engineer verifies and closes it. | Bought-in parts fail a requirement and the cause is at the supplier. |
| CAR | A corrective action request raised inside your own company, after an NCR, an audit finding or a customer complaint. | The department that owns the process, such as a line, the paint shop or maintenance. | The cause is in your own plant. |
| 8D report | A problem-solving method and report in eight disciplines, from the team (D1) to closure (D8), first published by Ford in 1987. Not a request: a way to answer one. | A cross-functional team where the cause is: the supplier for a SCAR, your plant for a customer complaint. | A customer asks for one, or the problem is serious, repeating or crosses departments. |
| CAPA | The corrective and preventive action system that holds every CAR and SCAR, its actions and the check that they worked. ISO 9001:2015 covers corrective action in clause 10.2. | Quality runs the system and the log; action owners do the work. | You need one list of every open corrective action, its age and status. |
| NCR | The record that a part or material did not meet its requirement, and what was done with it: scrap, rework, use as is or return. | Whoever finds it, then quality or the review board decides what happens to the parts. | Every nonconforming lot. A serious or repeat NCR on supplier parts leads to a SCAR. |
SCAR
- What it is
- A corrective action request sent to a supplier about parts, material or a service they provided. The customer writes the problem and the due dates and verifies the answer.
- Who does the work
- The supplier finds and fixes the cause in its process. Your supplier quality engineer verifies and closes it.
- Use it when
- Bought-in parts fail a requirement and the cause is at the supplier.
CAR
- What it is
- A corrective action request raised inside your own company, after an NCR, an audit finding or a customer complaint.
- Who does the work
- The department that owns the process, such as a line, the paint shop or maintenance.
- Use it when
- The cause is in your own plant.
8D report
- What it is
- A problem-solving method and report in eight disciplines, from the team (D1) to closure (D8), first published by Ford in 1987. Not a request: a way to answer one.
- Who does the work
- A cross-functional team where the cause is: the supplier for a SCAR, your plant for a customer complaint.
- Use it when
- A customer asks for one, or the problem is serious, repeating or crosses departments.
CAPA
- What it is
- The corrective and preventive action system that holds every CAR and SCAR, its actions and the check that they worked. ISO 9001:2015 covers corrective action in clause 10.2.
- Who does the work
- Quality runs the system and the log; action owners do the work.
- Use it when
- You need one list of every open corrective action, its age and status.
NCR
- What it is
- The record that a part or material did not meet its requirement, and what was done with it: scrap, rework, use as is or return.
- Who does the work
- Whoever finds it, then quality or the review board decides what happens to the parts.
- Use it when
- Every nonconforming lot. A serious or repeat NCR on supplier parts leads to a SCAR.
A filled-in example
Illustrative, not a benchmarkA SCAR for zinc plating on a steel bracket, the same one filled in on page 4 of the PDF (illustrative). Day 0 is the day the SCAR was issued; the dates asked for were containment by day 2, root cause and plan by day 10, actions done by day 30.
The example lot against the drawing
- Lot 0931: thinnest readings5 to 6 µmbelow 8 to 12
- Lots 0934 to 0938: lowest reading9.2 µmin 8 to 12
- Below 8 µm: 30 brackets measured at receiving, lot 0931
- In specification: 20 brackets measured at receiving, lot 0931
- Below 8 µm: 2600 brackets sorted in the suspect lots 0931 to 0933
- In specification: 1900 brackets sorted in the suspect lots 0931 to 0933
Zinc plating required 8 to 12 microns. 30 of 50 brackets from lot 0931 measured 5 to 6 microns. Sorting the suspect lots 0931 to 0933 found 2,600 of 4,500 below 8 microns. After the fix, the lowest of 250 readings on lots 0934 to 0938 was 9.2 microns.
- Problem: drawing 2217 rev B asks for zinc plating 8 to 12 microns. At receiving, 30 of 50 brackets measured from lot 0931 (60%) read 5 to 6 microns. The lot of 2,000 was quarantined and an NCR raised; readings, photos and 5 sample parts went with the SCAR.
- Containment, confirmed on day 1: 4,500 brackets in the three suspect lots sorted with a coating thickness gauge, 2,600 below 8 microns (57.8%): 1,150 of 2,000 at our receiving, 840 of 1,500 in transit and 610 of 1,000 at the supplier. Lot 0930, plated before the repair, was the comparison: 400 checked, none below.
- Occurrence cause: after a repair, the tank 3 rectifier was fitted with a meter shunt of the wrong rating, so its display showed about twice the real current and the brackets were plated at about half current. Confirmed: a reference meter read 280 A against 540 A on the display, and test panels came out at 5.4 microns as found and 10.3 microns after the right shunt was fitted.
- Escape cause: the once-a-shift thickness check took its part from tank 2, so nothing plated in tank 3 was measured. System cause: the repair procedure had no output check before plating restarted.
- Actions, all done by day 23: the right shunt fitted on day 3 (lot 0934 is the first good lot), 5 parts from every load in every tank measured from day 8, tanks 1 and 2 checked on day 11 (both within 2%), a reference meter check added to the repair procedure on day 15, and the PFMEA, control plan and training done on day 23. The supplier's evidence: 20 loads, 100 readings, all 9.0 to 11.4 microns.
Verification: lots 0934 to 0938 were measured at receiving, 50 brackets each, 250 readings with none below 8 microns (9.2 to 11.6). The SCAR closed on day 49. The supplier's scorecard shows the root cause and plan in 9 days against 10 asked and the actions done in 23 days against 30.
Common mistakes
No evidence
A SCAR without the requirement, the readings and photos invites an argument instead of an investigation.
No dates
Set a date for containment and for each part of the response, and chase them.
Only one cause
Ask why it was made and why the supplier's checks missed it. A response that fixes the occurrence but not the escape lets the next problem through the same gap.
No clean point
Ask which lot is the first known good one and how it is marked, so receiving knows when to stop sorting.
Accepting "operator error"
Send back a response that blames a person without saying why the process let it happen and why it was not caught.
Closing on the paperwork
Close only after the next lots show the problem has gone, not on the day the supplier says the actions are done.
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
In LeanSuite, when an inspector flags a defect the batch is quarantined and a SCAR with photos goes to Quality and Procurement, and the SCAR's lifecycle, including the days the supplier took to respond, feeds the supplier's scorecard.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- CAPA: corrective and preventive action, with a worked example
- 8D Problem Solving: The Eight Disciplines Method for Manufacturing
- 8D report template, for a supplier that answers in 8D form
- What is a nonconformance? The NCR process
- Is/Is Not Analysis: Problem Definition for Root Cause Analysis
- Supplier audit checklist: scored questions and findings from a supplier visit
- Approved supplier list: record the status change a SCAR leads to
Put it on the wall
FAQ
Supplier corrective action request (SCAR) form: common questions
SCAR stands for supplier corrective action request (some companies say supplier corrective action report). It is the formal request a customer's quality team sends when a supplier's parts or material fail a requirement, asking the supplier to contain the problem, find the root cause, fix it and send evidence that the fix works.
A CAR is raised inside your own company because the cause is in your process. A SCAR goes to a supplier because the cause is in theirs: they investigate and fix it, and you verify their answer before you close it. Both go in the same CAPA log.
When a supplier's parts fail a requirement and you need the cause removed, not only the parts replaced: a repeat problem, a problem that reached your line or your customer, a safety or fit and function problem, or a large share of a lot bad. A one-off with an obvious cause can usually go back with a note on the return.
There is no standard time; your supplier quality manual or purchase terms set it. The example on this page asks for containment in 2 days, the root cause and planned actions in 10 days and the actions done in 30, and closes after five good lots. Agree your dates with suppliers before a problem happens.
No. The SCAR is the request and the record of the problem; an 8D is one method the supplier can use to answer it. Many customers ask for the answer in 8D form, which is why pages 2 and 3 of this template follow the D1 to D8 sections.
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- Forklift inspection checklist23 pre-shift checks for a week on one page, a do-not-operate rule, and a defect and repair log.
- 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.
- Office 5S audit checklist25 checks written for offices and shared areas, five per S, scored 1 to 5, with a score summary and actions.
- Floor marking color guideA floor marking color standard with swatches, marks and line widths to fill in, and a floor marking check with a layout sketch.
- Shadow board plannerTool inventory with fetch time, a layout planned from each tool's outline size, a month of daily checks with 5S audit evidence, and a missing tool log.
- 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.
- Safety audit checklistThirty-four plant-wide safety checks answered Yes, No or N/A, scored by area, with a risk rating and an action for every No.
- 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.
- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
- TWI job breakdown sheetThe TWI Job Instruction breakdown of a job into important steps, key points and reasons, with a worked example and the four steps.
- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Maintenance KPI trackerMTBF, MTTR, availability and PM compliance per asset and month, plant figures from the totals, planned maintenance % and backlog in weeks.
- Daily huddle agendaA 15-minute start-of-shift stand-up in six timed blocks, with yesterday's SQCDP results, today's plan, actions and escalations.
- DMAIC project charter templateThe Define-phase charter on one page: problem and goal, metrics, scope, team and phase dates, with savings and a tollgate checklist.
- Water spider route plan (mizusumashi)A water spider's fixed route: stops with arrival times, what is delivered and collected, route time against the cycle, cart load and a trip log.
- Cost deployment matrixWCM cost deployment on paper and in Excel: loss quantities by process, causal and resultant losses, the cost of each loss, a Pareto and the projects that recover them.
- Equipment criticality analysisAssets scored 1 to 5 on six criteria with your own weights, ranked and sorted into classes A, B and C with a safety override and a suggested maintenance strategy.
- Bottleneck analysis worksheetEffective capacity per station from cycle time, parallel units, availability and yield, the bottleneck, takt and utilization, a queue cross-check and the five focusing steps.
- 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.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Nemawashi template (stakeholder plan)Plan the one-to-one conversations before a decision: who to talk to in what order, their concerns, what changed and where they stand.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- 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.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Sign-in sheet templateA training and meeting sign-in sheet, a visitor sign-in and out sheet, and an Excel register of attendance and visitors on site.
- 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.
- 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.
- Work instruction templateA one-page work instruction with key points and step times, and an Excel training record that flags re-checks.
- 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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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.