Industries · Manufacturing
The line is measured every hour. The sheet is keyed in at month end.
Hourly line control sheet, line clearance, maintenance round, 5S audit and shutdown permit. The same sheet your plant has used for fifteen years, digitised exactly as it is, filled at the machine and with no signal, with the finding on the plant plan and at its level: basement, ground floor, mezzanine, elevation +12.
What happens today
- The inspector measures net weight, cap torque and seal every hour, writes it in pencil on the sheet hanging beside the line, and someone keys it in when they have time. Nobody measures badly: nobody finds anything.
- The customer complaint arrives three weeks later: you open the month’s folder, hunt for the 03:40 sheet from C shift and decipher the handwriting of the operator who filled it.
- The changeover clearance is signed from memory once the line has been running half an hour, and the printed code carrying the previous format’s date turns up three pallets later.
Five plant jobs, with the role that does them today
- 01
Hourly line control and batch release
- Who does it today
- The line quality inspector, every hour; the quality assurance manager at batch closure.
- What is left
- Every value with its specification and its time, and the release as an approval carrying the document fingerprint and the server’s timestamp.
- 02
Line clearance and format changeover
- Who does it today
- The line supervisor with the lead machine operator, before starting the new SKU.
- What is left
- The photo of the first piece and of the printed code as mandatory fields: without them the form does not close and the line is not declared running.
- 03
Maintenance round and energy lockout
- Who does it today
- The shift maintainer, in the electrical room where there is no signal.
- What is left
- The lockout record with a photo of the padlock and the tag, and the finding turned into a task with a due date hanging off that asset.
- 04
5S audit per zone, on the plant plan
- Who does it today
- The area supervisor or the continuous improvement coordinator, zone by zone.
- What is left
- Every zone as a polygon drawn at its level, the score for each of the five S, and the zone’s trend audit after audit.
- 05
Planned plant shutdown, with contractors inside
- Who does it today
- The shutdown manager, with dozens of companies working at the same time.
- What is left
- The work permit approved through a workflow with the server’s timestamp, and outside personnel’s names and national IDs masked according to who is looking, on export too.
What has to be backed up, and in what format
No program makes anyone comply with DS 44. What DS 44 does say, in its article 72, is that the backing record be kept preferably in electronic format. That is not the vendor talking: it is the authority.
| What the regulation requires | What evidence PAIR produces |
|---|---|
| DS 44 art. 72 Backing record of preventive risk management Record and back up, documentarily and faithfully, all information tied to the management of occupational risks, and keep it preferably in electronic format. | Every filled form carries its owner, its fill time and its arrival time on the server, and exports by date range without reassembling the month’s folder. |
| DS 44 art. 73 Register of incidents and dangerous occurrences Record place, date and time, those involved, description, causes and corrective actions, safeguarding sensitive or confidential information about workers. | Those are exactly the fields a field record captures. Names and national IDs come out masked according to who is looking, on export too, and unmasking requires a written reason. |
| DS 594 art. 11 Order and cleanliness in the workplace Keep workplaces in good conditions of order and cleanliness, and take effective measures against insects, rodents and other pests. | The 5S audit per zone: the zone drawn on the plan at its level, the red-tag photo with its coordinate and its time, and the score as a field the trend comes from. |
| DS 76 art. 5 Site record file (subcontracting) The principal company keeps on site an up-to-date record file, on paper and/or digital medium, with the risk assessments and the minutes of the regulators’ inspections. | The whole shutdown in a single record: approved work permits, progress per work front and minutes, separated per contractor and filterable by period. |
The bodies named are the regulators. PAIR neither represents them nor carries their endorsement.
What you start with
A few, built for Chilean plants, used as they are or changed entirely. If your control sheet already exists on paper, you upload the scan and it comes out identical.
- Hourly line control sheet, with specification and disposition of the out-of-range value
- Line clearance and format changeover record, with photo of the first piece and of the printed code
- Batch release with dated approval and who authorises it
- Maintenance round per sector and per plant level
- Energy lockout and tagout record: padlock, tag, who locks out and who releases
- 5S audit per zone, with red tag, owner and closure deadline
- Forklift pre-use check
- Hot-work permit for the shutdown
- Equipment acceptance protocol after the shutdown: alignment, torque and tightness test
Demo
Bring us your control sheet
An hourly control sheet or a line clearance record you use today: in thirty minutes you will see it digitised and filled from a phone, at the machine and with no signal.
- Would you rather look at the plans first? See pricing.
- Still have questions? Check the FAQ.