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Updated
Welder continuity log template
A welder continuity log is the record that shows each welder's qualifications are still in force. It lists every welder and every process they are qualified for, with the last date they welded with it, so nobody keeps welding on a qualification that has lapsed. The two codes most shops work to, ASME Boiler and Pressure Vessel Code Section IX for pressure work and AWS D1.1 for structural steel, both keep a welder's performance qualification in force only while the welder keeps using the process: if six months go by without welding with a process, the qualifications for that process lapse, and the welder has to requalify or renew as the code sets out. Read the clause in the edition of the code you work to, and your customer's rules, which can be stricter. This template has the log, with columns for the welder, stamp, WPS, process, positions, thickness and diameter range, test date, last use, who verified it and the next lapse date. It also has 20 checks on the qualification records, the log and each job, and a worked example. The Excel version works out each lapse date six months after the last use, shows the days left from the review date, and flags anything due within 30 days or already lapsed.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Header fields for the shop, the code and the review date, and a table with columns for welder, stamp, WPS, process, positions, ranges, test date, last use, job or weld ID, verified by and next lapse date.Welder, stamp, WPS, processPositions and rangesTest date and last useVerified byNext lapse dateDue and lapsed flags20 checksWorked example
When to use it
When to use a welder continuity log
- In any shop that welds to ASME Section IX or AWS D1.1, from the day the first welder qualifies.
- At the monthly review, to see who is close to a lapse and give them work with that process in time.
- Before a code weld is assigned, to check the welder is qualified and current for its process, position and thickness.
- In a customer, authorized inspector or certification audit, to show continuity for every welder in one place.
How to fill it in
- 1
List every qualification
One row per welder per process, from the welder performance qualification record: stamp, WPS, process, positions, and the thickness and diameter ranges the test qualified.
- 2
Record last use from real welds
Each time a welder uses a process on a job, enter the date and the job or weld ID. A supervisor or inspector verifies the entry.
- 3
Let the log work out the lapse date
The next lapse date is six months after the last use. The Excel version works it out with EDATE and shows the days left from the review date.
- 4
Review it monthly
Sort by days left. Anyone within 30 days gets work with that process before the date; anyone past it is marked lapsed.
- 5
Stop lapsed welders on that process
Take the welder off jobs with that process and update the skills matrix or job cover matrix the same day. Requalify or renew as the code sets out.
- 6
Keep the records
File the qualification records with the log, and keep both for as long as the code, the customer and the contract require.
The rule in each code
ASME Section IX and AWS D1.1 continuity, side by side
Both codes tie continuity to the process, not to the position or the WPS. The rules are paraphrased here, not quoted: read the clause in your edition before you rely on them.
| ASME Section IX | AWS D1.1 | |
|---|---|---|
| Used for | Boilers, pressure vessels and piping built to the ASME code | Structural steel welding |
| The rule, paraphrased | A qualification for a process lapses when the welder has not welded with that process for six months or more (QW-322) | A qualification stays in force unless the welder has not used the process for more than six months |
| Kept current by | Welding with that process within the six months | Using that process within the six months |
| Also ended by | A specific reason to question the welder's ability | A specific reason to question the welder's ability |
| Check | The edition you build to, and your authorized inspector | The edition named in your contract documents |
Used for
- ASME Section IX
- Boilers, pressure vessels and piping built to the ASME code
- AWS D1.1
- Structural steel welding
The rule, paraphrased
- ASME Section IX
- A qualification for a process lapses when the welder has not welded with that process for six months or more (QW-322)
- AWS D1.1
- A qualification stays in force unless the welder has not used the process for more than six months
Kept current by
- ASME Section IX
- Welding with that process within the six months
- AWS D1.1
- Using that process within the six months
Also ended by
- ASME Section IX
- A specific reason to question the welder's ability
- AWS D1.1
- A specific reason to question the welder's ability
Check
- ASME Section IX
- The edition you build to, and your authorized inspector
- AWS D1.1
- The edition named in your contract documents
What to check
The 20 checks on the records, the log and each job
Seven checks on each welder's qualification record, eight on keeping the continuity log, and five the supervisor makes before giving a welder a job. The codes set the rules; these checks keep the log honest.
The qualification record
One record per test, kept with the log
- 1The record names the welder, the stamp or ID, the code and its edition, and the WPS the test was welded to
- 2The process is recorded, and whether it was manual, semi-automatic, machine or automatic
- 3Positions qualified are written as the range the code allows from the test, not only the test position
- 4Thickness and diameter ranges qualified are worked out from the test coupon using the code's tables and written on the record
- 5The filler metal group or classification, backing and the other variables the code lists are recorded
- 6Test results (visual, bend, radiography or other) are recorded with who examined them and when, and the employer has certified the record
- 7The record can be found from the log in under a minute
The continuity log
Kept current every month
- 8Every qualified welder has a row for every process they hold
- 9Last use is taken from a real weld (a job, a weld ID or a work order), never from memory
- 10Each entry is verified by a supervisor, an inspector or the welding coordinator, with the date
- 11The next lapse date is worked out from the last use, for each process
- 12The log is reviewed on a set day at least once a month, and the review is signed
- 13A welder due to lapse within 30 days is given work with that process, under the code's rules, before the date
- 14A lapsed qualification is marked lapsed on the day it lapses, and the welder stops using that process until requalified
- 15A welder whose work gives a specific reason to question their skill, such as repeated rejects, is reviewed whatever the log says
Before a weld is assigned
The supervisor's check
- 16The job's WPS, process, position and thickness are inside the welder's qualified ranges
- 17The welder's continuity for that process is current on the day of welding
- 18Customer or contract rules stricter than the code, such as extra tests or a shorter period, are known and applied
- 19The skills matrix or job cover matrix shows the same status as the log
- 20Records are kept for as long as the code, the customer or the contract requires
A filled-in example
Illustrative, not a benchmarkAn example: a fabrication shop's monthly review on 31 October 2026, with three welders and four qualifications (illustrative, the same as page 3 of the PDF and the Excel example sheet).
Days left on each example qualification at the 31 October review
- J. Ortiz, W-12, GMAW173 dayscurrent
- J. Ortiz, W-12, FCAW123 dayscurrent
- R. Patel, W-17, GTAW14 daysdue
- D. Kim, W-23, FCAWlapsed 11 days agolapsed
J. Ortiz GMAW 173 days left, J. Ortiz FCAW 123 days, R. Patel GTAW 14 days (due within 30 days), D. Kim FCAW lapsed 11 days before the review.
- J. Ortiz, stamp W-12, GMAW: last used on 22 October 2026 on job 5520. Lapses on 22 April 2027, 173 days away. Current.
- J. Ortiz, W-12, FCAW: last used on 3 September 2026. Lapses on 3 March 2027, 123 days away. Current.
- R. Patel, W-17, GTAW to ASME Section IX: last used on 14 May 2026. Lapses on 14 November 2026, 14 days away. Due within 30 days.
- D. Kim, W-23, FCAW: last used on 20 April 2026. Lapsed on 20 October 2026, 11 days before the review.
R. Patel was given the GTAW welds on the next job that week, verified by the inspector, which moved the lapse date six months on. D. Kim was taken off FCAW work on the job cover matrix the same day and booked for a requalification test, and the review asked why the lapse was not caught in September.
Common mistakes
Filling in the log from memory
A last-use date has to come from a real weld: a job, a weld ID or a work order. A date nobody can trace will not stand up in an audit.
One row per welder
Continuity runs per process. A welder busy on GMAW every day can still lapse on GTAW.
Reviewing only before an audit
A lapse found at the audit means code welds were made on a lapsed qualification. Review every month.
Letting the log and the skills matrix disagree
Supervisors assign work from the matrix they see. Update both on the same day.
Ignoring stricter customer rules
A contract can ask for more than the code, such as extra tests or a shorter period. Note it on the log.
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
A job cover matrix shows who is qualified to cover each job. LeanSuite builds it from skill levels and signed-off procedures, so you can cover an absence fast and spot single points of failure.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- Skills matrix template
- Training matrix template with expiry dates
- Weld inspection checklist: before, during and after welding
- Hot work permit template
- Welding machine inspection, as an app checklist in LeanSuite
- Closing Plant-Wide Skill Gaps in 90 Days: A Practical Framework
- Why One Employee Absence Can Shut Down Production Lines
FAQ
Welder continuity log template: common questions
A record showing that each welder has used each process they are qualified for recently enough to keep the qualification in force. It lists the last date of use for each process and the date each qualification would lapse.
Under ASME Section IX and AWS D1.1 it stays in force as long as the welder keeps welding with the process: six months without it and the qualification for that process lapses. A specific reason to question the welder's ability ends it too. Customers and contracts can set shorter periods.
The WPS is the written procedure for making a weld. The PQR records the test weld that proved the procedure. The WPQ records the test a welder passed, and the continuity log keeps that qualification current.
As your code sets out, usually with a new test, which some codes allow in a shorter form for renewal. Read the clause in your edition, and keep the welder off code work with that process until it is done.
Whoever your quality manual names, usually a welding supervisor, an inspector or the welding coordinator, who can see the job or weld record each entry comes from.
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- 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.
- 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.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- 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.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.