Free MES & Shop Floor tools
112 templates, calculators, worksheets and reference tables. Each runs in your browser and exports to PDF, Excel, Word or CSV.
Templates and forms
Plex Smart Manufacturing Data Source Request Template
A fill-in specification for requesting or documenting a Plex data source so analysts, IT and plant owners agree on fields, filters and refresh.
Plex Go-Live Readiness Sign-Off Template
Go or no-go document for a Plex site rollout covering data, training, integrations, shop floor hardware, support and rollback, with sign-off lines.
Shop Traveler Template
Generate a printable job traveler with job header, material, routing steps, inspection points and sign-off lines. Export to PDF, Word or Excel.
Routing Accuracy Audit Template
A document template to audit ERP routings against the real process: sequence, work center, setup and run time, tooling and yield.
Production Schedule Template
Generate a printable weekly production schedule with jobs, setups, due dates, assumptions, risks and sign-off lines.
Shift Handover Production Log Template
Fill in output, downtime, holds and open issues and download a shift handover note for the next supervisor.
Production Planning Meeting Agenda and Minutes Template
A ready agenda and minutes sheet for the weekly production planning meeting, with an action table and sign-off.
Overtime Request and Approval Form Template
A one page form that ties overtime to specific jobs, hours and cost so it can be approved quickly and reviewed later.
Hot Job Expedite Request Form Template
Make expedites a decision with a cost: record the job, the reason, which jobs get delayed and who approved it.
Production Schedule Change Request Form Template
A form to request, assess and approve changes inside the frozen window of a production schedule, with capacity impact and sign-off.
Schedule Freeze Window and Change Control Policy Template
A fill-in policy that defines frozen, slushy and open schedule zones, who can change them and how exceptions are logged.
Shift Production Report Template
A fill-in shift report covering output versus target, scrap, downtime, safety, staffing and handover notes, exported as a ready to print document.
Machine Downtime Log Template
A printable downtime log with loss categories mapped to the six big losses, ready for operators to fill in by hand or in Excel.
OEE Improvement Action Plan Template
A one-document plan for an OEE project: baseline, target, top losses, actions with owners and dates, and the review rhythm.
CNC Setup Sheet Template
A fill-in CNC setup sheet covering job data, work offsets, workholding, tools and operator notes, with PDF, Word and Excel export.
CNC Lathe Setup Sheet Template
A printable lathe setup sheet covering workholding, stickout, tool stations, offsets and first-piece checks, so the next operator can repeat the job.
Welding Production Daily Report Template
Summarize each shift of welding: crew, joints completed, hours, consumables used, delays and quality issues, in a clean exportable report.
Molding Shift Production Report Template
A shift report for a molding department capturing output, downtime, scrap and issues for the next shift.
Molding Process Window Study Record Template
A fill-in record for the approved process and a low, nominal, high process window study on a mold and machine combination.
Optical Assembly Build Traveler Template
Printable traveler for optical and laser module assembly: operations, cleanroom conditions, alignment checks and sign-offs.
Wafer Fab Process Traveler Template
A fill-in lot traveler for wafer processing with operation table, hold points, deviations and sign offs.
Worksheets
Infor VISUAL Shop Labor Ticket Log Worksheet
An editable log of labor entries by work order operation with hours, rate, setup versus run and computed labor cost.
Plex Downtime Reason Log and OEE Worksheet
Editable shift log of planned time, downtime, parts made and scrap that computes availability, performance, quality and OEE per workcenter.
Job Shop On-Time Delivery Tracker Worksheet
An editable tracker that computes days late per job and the shop on-time delivery rate from promised and actual ship days.
Line Balancing Worksheet
Fill in work content per station against takt time and see load percent, idle seconds, balance efficiency and balance delay for an assembly line.
SMED Changeover Reduction Worksheet
Break a changeover into elements, classify each as internal or external, set a target time and see the machine downtime you can remove.
Finite Capacity Scheduling Worksheet
Load jobs against a work center with setup, run time and available hours per day, and see the hours and days of work you are committing.
Daily Production Schedule Board Worksheet
An editable job board that totals setup and run hours per line so a scheduler can see whether the day fits the shift.
Changeover Sequence Planning Worksheet
List jobs in running order with setup and run minutes to see how much of the day is lost to changeovers and compare sequences.
Schedule Adherence Tracking Worksheet
Record planned and actual units per day with the miss reason to measure schedule attainment and find the biggest cause of misses.
Critical Ratio Job Sequencing Worksheet
Rank open jobs by critical ratio and slack so the most behind jobs run first. Editable table that exports to Excel.
Six Big Losses OEE Worksheet
An editable worksheet that records the six big losses per line and shift in minutes, computes OEE per row and totals each loss as a share of planned time.
SMED Changeover Analysis Worksheet
Break a changeover into steps, mark what can move outside machine stoppage, and total the minutes you recover.
Micro Stop Log Worksheet
Tally minor stops by cause on the line, convert them to lost minutes, and export a clean log for OEE analysis.
OEE Loss Pareto Worksheet
Enter losses by reason code, get minutes per event and totals, and use the list to pick the next improvement target.
Run Rate and Cycle Time Study Worksheet
Time three cycles per part, compare against the standard cycle, and see the speed percentage that drives the OEE performance factor.
Standard Work Combination Sheet Worksheet
Record each work element with manual, machine and walk times and get the operator's total cycle time to compare with takt.
CNC Tool List and Offset Log Worksheet
An editable tool list that tracks tool numbers, holders, stick-out and offsets, and flags the net wear on each tool.
CNC Tool Life Tracking Log Worksheet
An editable log of tool life in parts and cutting minutes, with tool cost per part so you can set change intervals.
Turning Insert Tool Life Log Worksheet
Track how many parts each insert edge produces, why edges were changed, and the resulting tooling cost per part.
Drilling Feeds and Speeds Planning Worksheet
List each hole with surface speed, feed per revolution and depth, and get RPM, feed rate and drilling time per hole automatically.
Lathe Tool Offset Record Worksheet
Keep a written record of geometry and wear offsets per turret station so you can rebuild a setup or spot tools that drift.
Turning Speeds, Feeds and Cycle Time Setup Sheet
An editable operation table that computes rpm, feed rate and cutting time per pass and totals the part's cutting time.
Mold Changeover Time Log Worksheet
Log each mold change by phase, total the minutes and see which jobs miss your changeover target.
Scientific Molding Viscosity Curve Worksheet
Log a rheology (viscosity curve) study at several injection speeds and see relative viscosity and shear rate index calculated per run.
Heat Treatment Furnace Load Worksheet
Build a furnace load sheet row by row: pieces, unit weight, section thickness and process, with total load weight and a planning soak time.
SMT Line Balancing Worksheet
List each SMT line station with its cycle time and see the bottleneck, line UPH and balance efficiency.
SMT Line Changeover and Feeder Setup Worksheet
Plan the daily SMT schedule with changeover, feeder setup and run time per job so you can see true line utilization.
Fab Step Cycle Time and X-Factor Worksheet
An editable route worksheet that adds queue, process and move time per step, calculates X-factor and flags the steps where lots wait longest.
Apparel Time and Action (TNA) Calendar Worksheet
An editable time and action plan that lists order milestones, owners, planned and actual days, and shows total delay.
Print Press Run Log Worksheet
An editable run log that computes total waste, waste percent and average run speed for every job on the press.
Packaging Line Downtime and OEE Log Worksheet
A shift-by-shift log that computes availability, performance, quality and OEE for each packaging line.
Calculators and simulators
Oracle Fusion OEE Work Center Calculator
Calculate overall equipment effectiveness for a work center from production reporting figures, and see how downtime moves OEE.
VISUAL Shop Load Versus Capacity Calculator
Enter load hours and shift pattern for a work center to see utilization, overload hours and the weeks needed to clear the backlog.
VISUAL Shop Resource Capacity and Load Calculator
Find available capacity hours, load percentage and the number of machines needed for a work center, plus an efficiency sweep.
OEE Calculator for Plex and MES Data
Compute overall equipment effectiveness and its three factors from a shift or day of production data, and see how rejects move the result.
Takt Time and Machine Count Calculator
Convert monthly demand, shifts and breaks into takt time, then find how many machines are needed at your cycle time and OEE.
Job Shop Setup Cost and Minimum Lot Size Calculator
See how setup cost is absorbed as lot size grows, and find the smallest order that breaks even or keeps setup under a chosen share of price.
Odoo Work Center Capacity Calculator
Work out how many units a work center can make per week and how loaded it is, using the same fields you enter in Odoo: capacity, time efficiency, OEE target, setup and cleanup.
WIP Cash Tied Up Calculator Using Little's Law
Estimate how much cash sits in work in process from output rate and flow time, and what a shorter flow time would release.
Bottleneck Analysis Calculator
Enter process time, machine count and OEE for three resources, then see weekly capacity, which one is the bottleneck, and how utilization rises with demand.
Drum Buffer Rope Buffer Sizing Calculator
Start from touch time and lead time, apply a buffer percentage, and get the buffer in hours and days, the three buffer zones and the expected WIP in front of the constraint.
Production Schedule Adherence Calculator
Measure how well the floor followed the plan: schedule attainment, on-time job completion, missed jobs and schedule stability after expedites.
Overtime vs Added Shift Cost Calculator
Compare the weekly cost of covering a machine-hour shortfall with overtime against running an extra shift.
Little's Law WIP and Lead Time Calculator
Turn work in process and daily throughput into average lead time, flow efficiency and the WIP cap needed to hit a lead time goal.
Minimum Batch Size and Setup Cost Calculator
Find what each changeover really costs and the smallest batch that keeps setup cost below a chosen share of unit cost.
Overtime vs Extra Shift Cost Calculator
Compare weekly overtime cost with the cost of running an extra crew when production is short of hours.
Queue Time vs Utilization Calculator (Kingman Formula)
Estimate average queue time at a work center from utilization, arrival variability and process variability.
Job Run Time and Completion Date Calculator
Estimate how many hours and calendar days a production order needs on one machine, given rate, OEE, setup and shift pattern.
Constraint Product Mix Throughput Calculator
Rank two products by throughput per bottleneck minute and see the best weekly mix when constraint time is limited.
Critical Ratio Dispatch Calculator
Enter days to due date, remaining work and operations left to get critical ratio, slack and the expected lateness for one job.
TEEP Calculator (Total Effective Equipment Performance)
Calculate TEEP from calendar time, scheduled time, downtime and production counts, and see how much capacity is hidden outside the schedule.
OEE World Class Gap Simulator
Enter your current availability, performance and quality, set a target, and see the OEE gap in points, units and margin per year.
SMED Changeover Reduction Calculator
Estimate the annual hours and cost recovered by moving setup work outside machine stoppage and trimming the rest.
OEE Improvement Payback Calculator
Convert a planned OEE improvement into extra units, margin, payback and ROI so the project can be funded on numbers.
Speed Loss and Micro-Stoppage Calculator
Separate the performance loss in OEE into reduced speed and minor stops, and see the parts each one costs per shift.
Bottleneck Improvement Throughput Gain Calculator
Find the real system throughput and annual value from improving the constraint, including when the next resource takes over.
Line Balancing Efficiency Calculator
Enter station cycle times and takt time to find the bottleneck, balance efficiency, balance delay and the theoretical minimum number of stations.
Pitch Interval Calculator
Calculate takt time and pitch (takt times pack-out quantity) to set the rhythm of production control and material withdrawal.
Lean Cell Operator Staffing Calculator
Work out how many operators a cell needs at a given takt time, allowing for walking time and personal allowances, and see utilization.
CNC Drilling Cycle Time Calculator
Calculate spindle speed, feed rate and total time for a drilling job with peck cycles, and see how peck depth affects time.
Constant Surface Speed G96 Spindle RPM Calculator
See what rpm your lathe will actually run under G96 as the diameter shrinks, where the spindle speed limit kicks in, and how long a facing cut takes.
Injection Molding OEE Calculator
Calculate availability, performance, quality and overall equipment effectiveness for a molding press from a shift or day of production data.
Cutting Speed to RPM and Feed Rate Calculator
Convert surface speed in m/min to spindle RPM and SFM, then calculate milling feed rate and material removal rate from tooth count and chip load.
Fab Equipment Utilization Calculator (SEMI E10 Style)
Break tool time into SEMI E10 style states and calculate availability, utilization and throughput efficiency.
Automotive Line Rate and Capacity Calculator
Convert cycle time, shifts and OEE into annual capacity, then compare to customer demand to get utilization, takt time and the OEE you need.
Required OEE for OEM Volume Calculator
Back solve the OEE a cell needs to deliver a customer volume plus flex, and see the headroom or shortfall at your current OEE.
Sewing Line Balancing Calculator
Calculate takt time, required operators, line balance efficiency and daily output for a sewing line from SAM and bottleneck time.
Garment SAM Daily Output and Labor Cost Calculator
Turn style SAM, operators, hours and line efficiency into daily output, labor cost per piece and days to complete an order.
China Golden Week Production Capacity Calculator
Estimate how many units a Chinese plant can really make across the Golden Week period and how much to pre-build or order early.
Reference tables
IFS Shop Order Status and Lifecycle Reference
A searchable table of the IFS shop order lifecycle: the main statuses, the events that move an order between them and what to check at each step.
Job Shop KPI Definitions Reference
Standard formulas and ERP data sources for the KPIs a small machine shop should track.
Shop Floor Dispatching Rules Reference
A searchable table of the common dispatching and sequencing rules, what each one sorts by, what it favors and where it fails.
Production Scheduling KPI Formula Reference
Every scheduling KPI a planner is asked for, with its formula, unit and the usual way it is misread.
OEE Formula Quick Reference Table
A searchable lookup of the standard OEE family formulas, with what each one needs as input and the usual pitfalls.
ISO 22400 Manufacturing KPI Reference
A plain language lookup of the manufacturing operations KPIs associated with ISO 22400, with the theme and the question each answers.
Downtime Reason Code Hierarchy Reference
A starter list of downtime reason codes arranged in a hierarchy, mapped to the six big losses and to planned or unplanned status.
OEE Six Big Losses Reference Table
Each of the six big equipment losses mapped to its OEE factor, with examples, where the data comes from and how to attack it.
Code and query generators
Checklists
Plex Production Scheduling Checklist
A grouped checklist covering master data, capacity, job readiness and daily routines for reliable scheduling in Plex.
Production Schedule Release Checklist
Check capacity, material, tooling, people, quality and communication before you release a schedule to the floor.
Daily Production Scheduling Meeting Checklist
A structured agenda for the daily scheduling meeting so late jobs, shortages and constraints are reviewed in the same order every day.
Production Order Release Readiness Checklist
A clear-to-build checklist to run before releasing a work order, so jobs do not stall after they hit the floor.
OEE Rollout Readiness Checklist
A checklist covering definitions, data capture, people and routines to complete before and during an OEE rollout.
SMED Changeover Improvement Checklist
A staged checklist for a single minute exchange of die workshop, from recording the current changeover to sustaining the new method.
CNC Pre-Run Setup Verification Checklist
A checklist for the operator or setup technician to confirm program, tools, offsets, workholding and safety before running production.
Press Brake Setup and First Piece Inspection Checklist
A shop floor checklist for press brake job setup, first piece verification and release to production.
Injection Press Startup and Shutdown Checklist
A practical checklist for starting up and shutting down an injection molding press, from guards and material to first-shot and purge steps.
Assessments
Plex Cloud MES Readiness Assessment
Ten questions to gauge whether your plant is ready to run on a cloud manufacturing platform such as Plex.
OEE Program Maturity Assessment
Ten questions that score your OEE practice from ad hoc to embedded, with next steps for each band.
CNC Shop Programming and Tooling Data Maturity Assessment
Score how well your shop manages NC program revisions, tool data, offsets and setup documentation, and see where to start.