Downloadable Excel spreadsheets
Free spreadsheets to take to the plant what the articles explain. They come with formulas already built: you fill in the yellow cells and the rest is calculated for you. Each one includes a "How to use" sheet with the steps, the formulas and the source of the method, and example values that you must delete before entering your own.
Maintenance
| Spreadsheet | What it is for | Article | |
|---|---|---|---|
| Preventive maintenance plan | List of tasks with frequency and last execution: calculates the next date and flags what is overdue. | Types of maintenance | Download |
| Failure log, MTBF and MTTR | Entry of breakdowns with start and end of downtime: MTBF, MTTR and availability per equipment. | MTBF, MTTR and availability | Download |
| OEE per shift | Shift-by-shift record of availability, performance, quality and OEE. | OEE | Download |
| Equipment criticality | Frequency times consequence: sorts the equipment into zones A, B and C. | Criticality analysis | Download |
| Life-cycle cost (LCC) | Comparison of two machines by their total cost over the whole service life, with a year-by-year breakdown. | Life-cycle cost | Download |
| Work order | Printable form with spare parts, technician hours, downtime hours and total cost. | Types of maintenance | Download |
Work study and processes
| Spreadsheet | What it is for | Article | |
|---|---|---|---|
| Time observation sheet | Stopwatch timing with the continuous or snapback method: standard time, pieces per hour, recording error and recommended cycles. | Stopwatch time study, Time study | Download |
| Line balancing | Tasks with times and predecessors: minimum stations, time of each station with a warning if it exceeds the cycle, and efficiency. | Line balancing | Download |
| Takt time and capacity per workstation | Takt time, cycle time and capacity of each workstation, bottleneck, and whether the line can meet the demand. | Takt time, Capacity and utilization | Download |
| Allowances and rest for physical effort | Sum of allowances, standard time and rest for physical effort with Murrell's formula. | Fatigue and rest breaks | Download |
| Learning curve | Projected against observed times, unit by unit, and learning rate from two measurements. | Learning curves | Download |
| Lead time and value stream | Working time against waiting time per stage, and takt, inventories and lead time using the data of a value stream map. | Lead time, VSM | Download |
| Flow process chart and spaghetti diagram | Flow process chart with the 5 symbols (events, time and distance) and a spaghetti diagram: floor plan with blocks, the route drawn as lines between them, and a comparison of the current and the proposed route. | Flow process chart, Spaghetti diagram | Download |
| Flow matrix between areas | From-to matrix: adds the outbound and return flow of each pair of areas and ranks the relationships from highest to lowest flow. | Plant layout | Download |
Quality, improvement and problem solving
| Spreadsheet | What it is for | Article | |
|---|---|---|---|
| Pareto of causes | Sorts the causes on its own, calculates the percentage and the cumulative total, marks the vital few and draws the Pareto chart. | Pareto chart | Download |
| FMEA | One row per failure mode: calculates the RPN and the priority, and the new RPN after the action. | FMEA | Download |
| Production leveling (Heijunka) | Daily quantity and repeating cycle per product, and a Heijunka box to fill in. | Heijunka | Download |
The spreadsheets are meant as a starting point: adapt the scales, frequencies and cut-offs to your plant.