Free Checklist Templates for Manufacturing

Manufacturing

OR

Continuous Improvement Checklist

Process Selection & Baseline

Identify the bottleneck process or cell

Walk the gemba with operators

Capture baseline OEE and cycle times

Build the current-state value stream map

Score the eight wastes against TIMWOOD

A3 & Countermeasure Planning

Draft the A3 problem statement

Run 5-why and fishbone analysis

Set SMART improvement targets

Prioritize countermeasures by impact and effort

Charter the kaizen team and sponsor

Pilot Implementation

Communicate changes at the tier board

Train operators on the new standard work

Pilot the countermeasure on one shift

Run SPC on the pilot output

Escalate to engineering for redesign

Standardize & Sustain

Update standard work and visual aids

Revise PFMEA and control plan

Schedule layered process audits

Capture before-and-after KPIs at 30 days

Recognize the kaizen team

Open a follow-up PDCA cycle

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Cycle Counting Checklist

Pre-Count Preparation

Pull the ABC cycle count list from ERP

Freeze inventory movement in the count zone

Confirm all transactions are posted

Stage scanners, count sheets, and labels

Brief counters on assignments and tolerance

Conducting the Count

Perform the blind count by location

Verify lot and heat traceability

Recount any variance over tolerance

Tag completed locations

Variance Investigation

Investigate root cause of variances

Document findings and disposition

Open a CAR for systemic variance patterns

Adjustment and Closeout

Post inventory adjustments in ERP

Generate the cycle count summary report

Sign off on the cycle count

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Daily Production Checklist

Pre-Shift Equipment Inspection

Verify LOTO points cleared after prior PM

Inspect guards, light curtains, and interlocks

Check lubrication at scheduled grease points

Test emergency stop on each work center

Confirm gauges within calibration date

Material and Kit Readiness

Pull the kit per work order BOM

Capture lot and heat numbers for traceability

Inspect raw material against incoming spec

Verify shelf-life on time-sensitive consumables

Safety and Compliance Walkthrough

Confirm operators wearing PPE per JSA

Deliver shift safety topic and near-miss review

Walk aisles and emergency exits for obstructions

Verify SDS binder current for in-use chemicals

Production Startup and First-Piece

Load CNC or PLC program at current revision

Verify tooling and offsets against setup sheet

Run first piece per FAI inspection sheet

Correct setup and re-run first piece

In-Shift Monitoring and Handover

Perform in-process inspection per AQL plan

Log hourly production counts against takt

Capture NCRs, downtime, and scrap counts

Segregate non-conforming parts and assign disposition

Brief next shift via handover log

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Data Backup and Recovery Checklist

Scope and Recovery Objectives

Inventory critical production systems

Define RTO and RPO per system

Flag ITAR or EAR-controlled technical data

Confirm regulatory retention requirements

Backup Configuration

Verify the 3-2-1 backup architecture

Validate the ERP database backup schedule

Configure PLM vault and CNC program capture

Confirm AES-256 encryption on backup targets

Apply ITAR access controls to backup copies

Execution and Verification

Run the scheduled full backup window

Review job logs and off-site replication

Attach verification evidence to the runbook

Recovery Drill

Restore the ERP database to sandbox

Restore a sample CNC program to a cell

Measure actual RTO against target

Record the drill outcome

Remediation and Closeout

Open a corrective action for the failed restore

Update the DR runbook with findings

Brief the plant manager and IT lead

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Demand Planning Checklist

Data Collection and Validation

Pull 24 months of shipment history from ERP

Reconcile shipments against open orders and backlog

Cleanse outliers and one-time events

Tag promotions and seasonality in the baseline

Confirm BOM and item-master changes since last cycle

Statistical Forecast Generation

Run the statistical baseline forecast

Review forecast accuracy against last cycle

Scan market and economic signals

Decide whether new product introductions need manual seeding

Seed launch curves for NPI SKUs

Sales and Marketing Input

Distribute baseline to sales for override

Collect promotional calendar from marketing

Capture the consensus override per family

Supply and Capacity Reconciliation

Compare consensus demand to plant capacity

Escalate capacity gaps to the S&OP meeting

Confirm long-lead-time material with purchasing

Set safety stock by SKU criticality

Consensus Meeting and Sign-Off

Hold the executive S&OP meeting

Lock the consensus forecast in the planning system

Distribute the published forecast

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Electrical Systems Maintenance Checklist

Pre-Work LOTO and Safety

Pull the one-line diagram and PM history

Apply LOTO per equipment-specific procedure

Verify zero energy with a rated meter

Don NFPA 70E arc-flash PPE for the task

Power Distribution Systems

Inspect breakers for arc tracking and pitting

Thermal-image bus bars and lug connections

Test protective relay trip settings

Torque-check panel connections to spec

Measure ground electrode resistance

Transformers and Motors

Sample transformer oil for DGA analysis

Megger transformer windings at 1000V

Run vibration analysis on motor bearings

Verify motor shaft alignment with laser tool

Lighting and Control Systems

Replace failed high-bay LED fixtures

Run 90-minute emergency lighting discharge test

Verify exit-sign battery backup

Torque-check PLC cabinet terminals

Backup Power Systems

Run generator under 30% load bank for two hours

Measure ATS transfer time

Test UPS battery runtime

Verify diesel fuel level and quality

Closeout and CMMS Update

Open NCR for thermal hot connections

Open NCR for transformer insulation failure

Schedule service call for the generator

Update CMMS with PM completion

Remove LOTO and brief next shift

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Employee Offboarding Checklist

Pre-Departure Coordination

Confirm the last working day with HR

Classify the departure type

Coordinate the security escort plan

Catalog role-specific system access

Notify the production scheduler of capacity impact

Assign coverage on the cell or shift

Knowledge Transfer and Handover

Document the status of open work orders

Reassign open NCR and CAR ownership

Transfer PLM check-ins and drawing ownership

Walk the replacement through machine quirks

Update setup sheets with undocumented tricks

Asset and Tooling Recovery

Recover personal LOTO locks and keys

Reconcile tool crib check-outs against the log

Collect issued PPE and uniforms

Retrieve laptop, MES tablet, and RF scanner

Sign off on the asset recovery inventory

Systems and Access Revocation

Disable ERP and MES accounts

Revoke PLM and document control access

Remove from the ITAR-controlled access list

Deactivate the badge at all plant entries

Forward email and remove from distribution lists

Exit Interview and HR Closeout

Conduct the exit interview

Finalize pay, PTO payout, and expenses

Terminate benefits effective the last day

Update OSHA and customer training records

Archive the personnel file

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Employee Onboarding Checklist

Pre-Day-1 Setup

Complete I-9 and E-Verify

Capture role classification and pay details

Send offer letter for signature

Initiate background check and drug screen

Provision IT accounts and badge

Stage PPE and uniform issue

Day 1 Orientation

Welcome and HR paperwork review

Deliver HazCom and SDS training

Cover LOTO awareness training

Walk emergency action plan and muster point

Tour the plant with the supervisor

Role-Specific Training

Issue forklift or PIT certification training

Train on work instructions for the assigned cell

Pair with a mentor for on-the-job training

Train on quality and inspection requirements

Confirm role requires PIT operation

30/60/90 Day Milestones

Hold the 30-day supervisor check-in

Verify training matrix completion at 60 days

Conduct the 90-day probationary review

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Energy Efficiency Audit Checklist

Audit Preparation

Pull 24 months of utility bills

Set the ASHRAE audit level and scope

Schedule the on-site walkthrough

Gather one-line diagram and equipment list

Building Envelope and Lighting

Inspect envelope, roof, and dock seals

Inventory lighting fixtures and run hours

Test occupancy and daylight controls

Photograph LED retrofit candidates

HVAC and Compressed Air

Survey RTUs, chillers, and air handlers

Log compressed air pressure and schedule

Quantify compressed air leaks during off-shift

Verify VFDs on fans, pumps, and compressors

Process Equipment and Motors

Inventory motors over 5 HP with NEMA class

Review oven and furnace idle schedules

Assess heat recovery opportunities

Findings, ROI, and Reporting

Build a calibrated energy model

Calculate kWh and therm savings per ECM

Confirm utility rebate eligibility

File rebate pre-approval applications

Present findings to plant leadership

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Environmental Compliance Checklist

Hazardous Waste Management

Confirm RCRA generator status

Inspect satellite accumulation areas

Verify weekly central accumulation inspections

Reconcile e-Manifest shipments against logs

Verify universal waste and used oil handling

Air Emissions

Confirm Title V or synthetic minor status

Review CEMS and stack test records

Inspect baghouses, scrubbers, and thermal oxidizers

Audit VOC and HAP usage logs

Document a deviation report

Water Discharge and Stormwater

Pull NPDES DMR sampling results

Review SWPPP and stormwater inspections

Verify SPCC plan and secondary containment

Test and document outfall samples

Confirm pretreatment compliance with POTW

Reporting and Sign-Off

Track Tier II and TRI deadlines

Review open NOVs and consent orders

Sign off on the quarterly compliance review

Corrective Action and Agency Notification

Open a CAR for each finding

Coordinate self-disclosure with counsel

Schedule the effectiveness verification

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Environmental Compliance Review

Hazardous Waste Management

Confirm RCRA generator status

Inspect satellite accumulation areas

Verify 90-day accumulation start dates

Reconcile e-Manifest shipments to TSDF receipts

Confirm RCRA personnel training is current

Air Emissions Compliance

Pull the Title V deviation log

Verify CEMS calibration and data availability

Compare VOC and HAP totals to permit caps

Review baghouse and scrubber PM history

File the Title V deviation report with the state agency

Water Discharge Compliance

Sample stormwater outfalls per SWPPP

Compare DMR results to NPDES permit limits

Inspect SPCC secondary containment

Verify POTW pretreatment monitoring

Submit 24-hour NPDES non-compliance notice

Chemical Inventory and EPCRA Reporting

Reconcile chemical inventory against the SDS library

Calculate EPCRA Tier II threshold quantities

Determine TRI Form R applicability

Audit HazCom secondary container labels

Prepare TRI Form R submissions

EMS Review and Sign-Off

Review ISO 14001 objectives and targets progress

Close out findings from the prior internal audit

File quarterly regulatory reports

Schedule EHS training refreshers

Sign off on the quarterly compliance review

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Equipment Maintenance Checklist

Pre-PM Setup and LOTO

Pull the PM work order from the CMMS

Coordinate the production downtime window

Apply LOTO per 29 CFR 1910.147

Stage required PPE and tooling

Inspection and Condition Assessment

Walk the asset for visible wear and damage

Inspect electrical panels, conduit, and cabling

Check lubrication points and fluid levels

Record vibration and temperature readings

Determine overall asset condition

Corrective Action

Open a corrective work order in the CMMS

Tag the asset out of service if unsafe

Notify the maintenance lead and production supervisor

Routine Cleaning and Lubrication

Clean external surfaces and clear chip buildup

Clear obstructions from moving parts and travel paths

Lubricate per the OEM PM schedule

Replace filters and top off fluids

Safety and Compliance Verification

Verify machine guards are intact and interlocked

Test E-stops and light curtains

Confirm SDS and HazCom postings are current

Capture maintenance tech sign-off

Return to Service and Closeout

Remove LOTO and energize the equipment

Run a function test and first piece

Close the work order in the CMMS

Hand off to production at shift change

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Equipment Maintenance Checklist

PM Setup and Lockout/Tagout

Pull the PM work order from the CMMS

Coordinate the downtime window with production

Apply lockout/tagout per the machine-specific procedure

Stage tools, spares, and SDS for chemicals used

Mechanical and Electrical Inspection

Inspect guards, interlocks, and e-stops

Inspect frame, fasteners, and weldments for wear

Check electrical terminations and grounding

Log any defects requiring corrective action

Open a corrective work order for the defect

Service and Wear-Part Replacement

Replace filters per the OEM PM schedule

Inspect and replace belts at wear limit

Lubricate per the asset lube chart

Service bearings and check for play

Record fluids, filters, and parts consumed

Functional Test and Release

Remove LOTO and restore energy

Run the dry-cycle and check for abnormal noise

Verify safety circuits and e-stop function

Run a first-piece check with production

Close the PM and release to production

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Finished Goods Quality Assurance Checklist

Visual Inspection

Confirm work order and lot match the traveler

Pull the AQL sample per ANSI Z1.4

Inspect surfaces, finish, and labels for defects

Verify color and finish against the boundary sample

Write an NCR and segregate the rejected lot

Dimensional Accuracy

Pull calibrated gauges from the tool crib

Measure CTQ dimensions per the inspection sheet

Run the CMM program on first and last pieces

Confirm Cpk meets the control plan threshold

Functional Testing

Run the end-of-line functional test sequence

Verify performance against customer acceptance criteria

Conduct the hi-pot or leak test per the control plan

Verify safety interlocks and guard sensors

Route failed units to MRB for disposition

Documentation and Traceability

Record serial and lot numbers in the MES

Capture raw material heat and lot for traceability

Sign and attach the CofC and CofA

Verify release meets PPAP and ISO 9001 requirements

Packaging and Storage

Inspect packaging against the customer pack-out spec

Apply ESD or moisture-barrier protection where required

Confirm carton labels include barcode and handling marks

Stage finished goods in the FG bonded location

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Fire Safety and Emergency Preparedness Checklist

Fire Safety Equipment Inspection

Verify extinguisher accessibility per NFPA 10

Check monthly extinguisher inspection tags

Tag and remove failed extinguishers from service

Test fire alarm panel and pull stations

Inspect emergency lighting and exit signs

Confirm quarterly sprinkler inspection per NFPA 25

Emergency Evacuation Plan

Review the written EAP per 29 CFR 1910.38

Post evacuation routes and assembly points

Train all employees on evacuation procedures

Designate fire wardens by department

Run a full-facility evacuation drill

Document drill deficiencies and corrective actions

Employee Safety Training

Deliver annual fire safety training

Run hands-on extinguisher training (PASS technique)

Brief the floor on hot work and combustible-dust hazards

Onboard new hires with fire safety orientation

Upload training attendance and acknowledgments

Hazardous Materials Management

Store flammables in approved cabinets per NFPA 30

Label containers per HazCom 2012 and NFPA 704

Verify ventilation in chemical-use areas

Stock spill kits and verify spill response training

Reconcile the hazardous materials inventory

Update SDS binder and refresh HazCom training

Facility Maintenance and Housekeeping

Clear work areas of combustible debris

Inspect electrical panels and wiring

Verify machinery PMs cover overheating risks

Run combustible-dust cleaning per NFPA 652

Confirm exits and egress paths are clear

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Hazardous Materials Handling Checklist

Personal Protective Equipment

Match PPE to the SDS hazard section

Verify HazCom and respirator training is current

Pull operators with expired training off the task

Inspect PPE for damage before each use

Confirm PPE storage and decon stations are stocked

Storage and Labeling

Verify GHS labels on every secondary container

Segregate incompatibles per the storage matrix

Inspect secondary containment and flammable cabinets

Reconcile the chemical inventory against SDS binder

Mark satellite accumulation areas correctly

Spill Response and Cleanup

Verify spill kits are stocked at each point of use

Walk the spill response plan with the floor crew

Log the spill drill or live event

File the written incident and disposal record

Open a CAR for any reportable release

Transportation of Hazardous Materials

Classify the shipment per 49 CFR 172.101

Apply IATA or IMDG requirements for air or ocean

Inspect UN-spec packaging and closure

Mark, label, and placard the load

Verify the hazmat employee certification on the BOL signer

Confirm carrier emergency response info on the shipping paper

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Incoming Materials Inspection Checklist

Documentation and Identification

Match the packing list to the open PO

Verify the mill cert or certificate of compliance

Record lot and heat numbers for traceability

Confirm the part rev matches the current ECN

Check shelf life on date-sensitive material

Physical Condition and Packaging

Inspect outer packaging for damage or tampering

Photograph any damage or contamination

Verify packaging suits the material type

Stage the receipt in the quarantine bay

Dimensional and Material Verification

Count quantity received against the packing list

Measure critical dimensions per the AQL sampling plan

Run PMI on metallic alloy stock

Record the inspection result

Non-Conformance Handling

Open an NCR in the QMS

Apply red hold tags and segregate to the MRB cage

Notify the buyer for supplier disposition

Record the MRB disposition

Release to Stock

Update the receipt in the ERP

Move material to the assigned stock location

Release the lot for production use

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Inventory Control Checklist

Pre-Count Setup

Run ABC analysis in the ERP

Freeze inventory transactions in the ERP

Print count sheets and bin labels

Brief counters on the count SOP

Physical Count Execution

Count raw material and WIP locations

Count finished goods and MRO locations

Cycle count A items at the bin level

Flag obsolete and slow-moving stock

Submit count sheets to inventory control

Reconciliation and Variance Investigation

Compare counted quantities against ERP on-hand

Classify variance against materiality threshold

Investigate root cause for material variances

Post inventory adjustments in the ERP

Disposition obsolete stock to scrap or write-off

Reorder Parameter Tuning

Pull 12-month usage and lead-time data

Recalculate reorder points and safety stock

Resize kanban quantities at line-side bins

Review supplier scorecards with purchasing

Push updated parameters to the ERP item master

Closeout and Reporting

Publish inventory accuracy and turn metrics

Sign off on the quarterly inventory review

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Inventory Management

Receiving and Incoming Inspection

Match packing slip against the open PO

Inspect pallets and cartons for transit damage

Open a receiving NCR for the damaged lot

Capture lot, heat, and certificate of conformance

Run incoming inspection per the sampling plan

Receive against the PO in the ERP

Putaway and Storage Discipline

Putaway to the system-directed bin location

Verify FIFO rotation on shelf-life material

Segregate hazardous material to flammable storage

Update bin labels and rack signage

Inventory Monitoring and Replenishment

Review reorder point and kanban triggers

Walk the floor for empty kanban bins

Flag slow-movers and obsolete stock

Release replenishment POs and expedite at-risk items

Cycle Counting

Generate the daily cycle count list

Count blind without showing system quantity

Investigate variance before posting an adjustment

Post the inventory adjustment in the ERP

Reporting and Continuous Improvement

Update inventory accuracy and turn metrics

Review recurring variance root causes at the weekly Gemba

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ISO 14001 Environmental Management Checklist

Environmental Policy and Planning

Endorse and publish the environmental policy

Update the significant aspects register

Refresh the legal and other requirements register

Set environmental objectives and KPIs

Build the EMS implementation program

Implementation and Operation

Assign EMS roles per clause 5.3

Deliver EMS awareness and HazCom training

Verify operational controls on significant aspects

Reconcile the SDS binder and chemical inventory

Test the spill response and emergency plan

Monitoring and Measurement

Track environmental KPIs against targets

Calibrate environmental monitoring instruments

Evaluate compliance with the legal register

Record monitoring period results

Internal Audit and Management Review

Conduct the internal EMS audit per ISO 19011

Open non-conformities and corrective actions

Verify corrective action effectiveness

Hold the management review meeting

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ISO 9001 Compliance Checklist

Context of the Organization (Clause 4)

Document internal and external issues

Map interested parties and their requirements

Define the QMS scope and exclusions

Map QMS process interactions

Publish the context and scope document

Leadership and Commitment (Clause 5)

Hold the management commitment review

Reissue the quality policy at current rev

Cascade quality objectives to functions

Assign QMS roles and authorities

Brief supervisors on the process approach

Planning and Risk Management (Clause 6)

Run the risk and opportunity workshop

Update the QMS risk register

Refresh PFMEAs for impacted processes

Set measurable quality objectives with KPIs

Plan the QMS change-control workflow

Support and Resources (Clause 7)

Verify resource adequacy across the QMS scope

Audit the competence and training matrix

Close training gaps before audit week

Inspect calibration and infrastructure status

Audit document control and the master list

Operation and Internal Audit Readiness (Clause 8)

Verify production planning and traveler controls

Confirm customer requirement review records

Validate first-article inspection records

Audit nonconformance and CAR closure logs

Sign off internal audit readiness

Open corrective action for unresolved findings

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IT Systems Maintenance Checklist

Network Infrastructure

Patch IT-side switches and firewalls

Review OT network segmentation boundaries

Monitor shop-floor traffic for anomalies

Capture config backups for network gear

Test failover on redundant ERP paths

Software and Applications

Apply ERP patches in the test environment

Review MES error logs from the past cycle

Validate ERP-to-MES integration handoffs

Conduct quarterly user access review

Check PLC firmware against vendor advisories

Data Management

Run backups of ERP and MES databases

Test restore from backup into sandbox

Escalate failed restore to IT management

Audit master-data integrity in the item master

Verify historian retention against compliance windows

Review query performance on production reports

Hardware Maintenance

Inspect server room and shop-floor cabinets

Test UPS runtime on production servers

Schedule UPS battery replacement

Verify cooling in MDF, IDF, and shop panels

Inspect ruggedized shop-floor terminals

Close out the maintenance cycle

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Kaizen Event Checklist

Pre-Event Preparation

Draft the kaizen charter and target metrics

Select the cross-functional team

Pull baseline OEE, scrap, and cycle-time data

Book the gemba room and reserve the cell

Brief area leadership and floor operators

Day 1 — Charter and Current State

Hold the team kickoff and review the charter

Walk the gemba and observe the process

Build the current-state process map

Tag the seven wastes on the map

Days 2-3 — Improvement Design

Brainstorm and prioritize countermeasures

Draft the future-state map

Trystorm changes on the cell

Capture before-and-after measurements

Days 4-5 — Standardize and Pilot

Update standard work and visual controls

Train operators on the new standard work

Run the pilot against target metrics

Hold the report-out with leadership

Sustain and 30-Day Follow-up

Open a CAR for unresolved gaps

Audit standard-work adherence at 30 days

Re-train operators on the standard

Document lessons learned in the A3

Close the event in the kaizen tracker

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Logistics and Transportation Checklist

Transportation Planning

Pull next week's shipping demand from ERP

Classify shipments by mode and service level

Review carrier scorecard for OTD and damage

Tender loads to carriers via TMS

Inbound Coordination

Confirm supplier ship dates against MRP

Schedule inbound dock appointments

Verify packing slips against PO at receiving

Open a supplier NCR for the discrepancy

Compliance and Documentation

Generate BOL and commercial invoice

Prepare hazmat shipping papers and labels

Complete export documents for international freight

File shipping records for audit retention

Risk and Loss Prevention

Verify cargo insurance covers declared value

Apply tamper-evident seals to FTL trailers

Brief the contingency plan for lane disruption

Performance Review

Pull weekly OTD and damage KPIs from TMS

Audit freight invoices against tendered rates

Capture customer delivery feedback

Review KPIs in the weekly logistics huddle

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Machine Maintenance Checklist

LOTO and Safety Setup

Notify the operator and shift lead

Apply lockout/tagout per machine procedure

Verify zero energy state

Don required PPE for the task

Clear and barricade the work zone

Routine Inspection

Walk-around for wear, damage, and leaks

Check belts, chains, and couplings

Verify guards, interlocks, and E-stops

Record overall machine condition

Component Service

Service air and coolant filters

Inspect electrical connections in the cabinet

Lubricate bearings and ways

Check hydraulic and pneumatic pressure

Verify gauge calibration is current

Corrective Action

Open a corrective work order in the CMMS

Tag the machine with operating restrictions

Closeout and Return to Production

Reinstall guards and remove LOTO

Run a functional test and verify E-stops

Close the PM work order in the CMMS

Hand the machine back to the operator

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