Assessment

Operational Baseline Assessment & Gap Report (fillable)

A structured, fillable assessment that captures baseline scores across Safety, Quality, Delivery, Cost, and Reliability; records evidence; prompts root-cause thinking; and converts findings into prioritized improvement opportunities and 90-day pilot candidates.

Interactive Tool

Operational Baseline Assessment & Gap Report (fillable)

Purpose: Quickly establish an operational baseline across Safety, Quality, Delivery, Cost, and Reliability (S,Q,D,C,R), capture evidence, surface root causes, and convert findings into a prioritized set of owner-led improvement pilots.

How to use: Work with a small cross-functional team. For each capability area, pick the score that best reflects current capability (1 = critical gap, 5 = consistently strong). Use the evidence checklist to validate your scores. Use root-cause prompts to focus analysis on systems, not people. For improvement opportunities, estimate impact and implementation ease to help prioritize pilots for the next 90 days.

Use your site or team identifier or leave blank to auto-generate.
Who completed this assessment? Include role(s) and team.
YYYY-MM-DD
Where was the assessment performed?
1 = critical safety gaps and frequent incidents; 5 = strong hazard controls, low incident rate, proactive hazard elimination.
1 = frequent defects and rework; 5 = robust controls and low defect rates.
1 = frequent late deliveries or long lead-time variability; 5 = consistent on-time delivery and predictable lead times.
1 = high waste / high unit cost; 5 = efficient processes and strong cost controls.
1 = frequent breakdowns or process failures; 5 = predictable uptime and dependable processes.
Explain evidence or borderline judgments that affected your scores.
Choose all that apply; add notes in Scoring notes.
Consider: Are hazards identified and eliminated? Are controls passive or active? Are near-misses reported and acted on? Are responsibilities and competencies clear? What system or design gaps explain incidents?
Consider: Where do defects originate? Are inspection points upstream or downstream? Are standard work and error-proofing in place? Are suppliers or upstream processes causing variation?
Consider: What causes variability in lead time? Are bottlenecks stable or shifting? How reliable are scheduling and material availability?
Consider: Where is waste happening (overproduction, waiting, motion, defects)? Are processes designed for flow? Are inventories masking issues?
Consider: Are failures random or systemic? Do you have failure modes analyzed? Are maintenance practices reactive or proactive?
For each opportunity estimate Impact (1–5) and Ease (1–5). A simple prioritization heuristic: higher Impact × Ease indicates a promising pilot. Assign an owner and define clear 90-day outcomes.
State a measurable 90-day objective, key measures, and the first experiments or actions.
List the top 5 opportunities by title, owner, and 90-day objective in priority order. Explain why each made the list.
Provide a concise summary for leaders: 3-line baseline, top risks, top 3 recommended pilots (owner, expected impact), resource asks, and 90-day timeline.
List next steps, responsible person, and target dates for the first 30 days.
Select yes to include the executive summary and top 5 opportunities in a printable report.
If approval is needed, summarize required resources, estimated cost, and who must sign off.
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