What's inside
Seven working files that take you from "where does this plant actually stand?" to a running 90-day improvement system — assessment first, then the rollout, the daily forms, and the supervisor training to hold the gains.
Workbook · Excel
Plant Assessment Workbook
The heart of the kit: 80 audit criteria across 10 categories, every one written as something you can walk out and verify on the floor — not an opinion survey.
- Score each criterion 1–5, with the evidence standard spelled out for every level
- Dashboard builds itself from your scores: category scores, overall plant score, bar and radar charts
- Formula-driven maturity verdict, from "Foundation needed" to "World-class trajectory"
- Top Gaps sheet names your five weakest categories and gives you the action table to work them
Workbook · Excel
KPI Dashboard Pack
A 12-month tracker for the six numbers that tell you whether the plant is actually improving — set targets once, enter actuals monthly, and the variance math is done for you.
- OEE %, scrap %, on-time delivery %, unplanned downtime hours, safety incidents, inventory turns
- Target vs. actual vs. variance for every month, with ahead/behind colour coding
- OEE calculator with a fully worked example that lands at 80.0% — check your own line against it
- Definitions sheet: what each measure means, its formula, where the data comes from, and how often to review it
Workbook · Excel
5S & TPM Rollout Plan
The 12-week rollout, week by week: baseline and announce, Sort and Set in Order, Shine and Standardize, sustain systems, then review and re-audit.
- 49 concrete actions, each with an owner role and a measurable "done when" test
- Operator autonomous-maintenance steps 1–3 built into the plan, plus the PM calendar go-live
- Red tag log, ready for the first sort event
- 20-task daily/weekly operator TPM checklist with the standard for "good" written out for every task
Printable forms · PDF
Audit Forms Pack
Four print-and-carry forms, one per page, with plant, area, date, and auditor lines — the paper side of the system your auditors and shift leads use every week.
- 5S audit score sheet — 25 checks across the five S's, scored out of 125
- Layered process audit form — 12 station checks with a findings-to-action table
- Gemba walk observation card — standard vs. actual vs. gap, with the coaching prompts
- Standard work sheet — steps, key points, and times, with revision and approval lines
Training · PowerPoint
Supervisor Training Deck
A 20-slide deck in 8 modules that trains your front-line leaders to run the system you just rolled out — leader standard work, tier huddles, 5S sustain, problem response, coaching, the numbers, and a first-30-days plan.
- Worked 5 Whys and fishbone examples from real production problems
- OEE worked numerically on the slide, not hand-waved
- Full speaker notes on every slide — facilitation guidance plus a floor example for each topic
Guide · PDF
Facilitator Guide
Everything the person running the training session needs: room and materials setup, then timed half-day (about 3.5 hours) and full-day (about 6.5–7 hours) plans.
- Step-by-step instructions for all four training exercises
- Answers and talking points — model 5 Whys chain, OEE walkthrough, what a good escalation sounds like
- Slide-by-slide timing table, five pushback responses, and the two-week / 30-day follow-up mechanism
Guide · PDF
Implementation Guide
The 11-page master how-to that ties the whole kit together: how to run an honest assessment, read the dashboard without fooling yourself, and sequence the first 90 days.
- The 90-day sequence in three phases, with tier-meeting charters and layered-audit cadence by level
- A full worked example — a plant that scores 2.1 and cuts changeover from 74 to 51 minutes by day 90
- Seven named failure modes — audit inflation, huddle decay, the red-tag graveyard, and more — each with its counter