Book companion resource · Rubric
Wrench-Time Self-Audit
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← Back to toolkit · Browse by chapterThe Chapter 1 follow-a-crew exercise, formalized for ongoing quarterly use. The number you track over time to prove the installation is working.
Companion to: Fix the System, Chapter 8. Prerequisite: read Chapter 1 (The Wednesday Crew That Did Nothing) and do the first follow-a-crew audit using that chapter's companion Field Audit Sheet. Who uses it: a designated observer. Usually the maintenance manager or a trusted supervisor. The same observer over time produces the most consistent series. Cadence: once per quarter per crew. Same day-of-week, same shift pattern if possible.
Why repeat the measurement
One wrench-time measurement gives you a baseline. Two measurements, three months apart, give you a trend. Four quarterly measurements give you a twelve-month arc of your installation.
You cannot manage what you do not measure. You cannot prove an installation worked without a number that moved. The quarterly wrench-time audit is the proof.
Audit protocol
Before the audit day
- Pick a normal Wednesday (or whatever day is most representative — avoid shutdown days, start-up days, and audit-visit days).
- Pick a crew. Rotate crews across quarters if you have more than one — get a read on the plant, not just one crew.
- Tell the crew lead you are doing the audit. Be straight. Do not pretend.
- Pull last audit's number for reference. Write it on your clipboard.
During the audit
Use the same time-stamped log method from the Chapter 1 Field Audit Sheet. Every activity change, a new row. Mark ✓ for "on asset" only when a crew member has hands physically on an asset doing maintenance work.
This worksheet focuses on the END-OF-DAY rubric — do the timestamped logging on the Chapter 1 field audit sheet, then bring your results here.
After the audit — rubric scoring
Beyond just the wrench-time percentage, score the crew on four execution-stage disciplines:
Rubric — Execution stage quality
Dimension 1 — Pre-Job Briefing
Observed: did the crew conduct a pre-job briefing at the asset before starting?
| Score | What you observed |
|---|---|
| 3 — Installed | Crew lead ran a 4-item briefing (scope, lockout, assignment, questions) at the asset, taking 3-7 minutes. |
| 2 — Partial | Briefing happened but was rushed (<2 min), skipped one of the four items, or was conducted in the shop rather than at the asset. |
| 1 — Theater | Crew "discussed the job" informally en route but no structured briefing occurred. |
| 0 — Absent | No briefing of any kind; crew arrived at asset and began work. |
Your score: _____
Dimension 2 — Lockout Verification
Observed: for any lockout events, was the isolation verified (tested) beyond just hanging the lock?
| Score | What you observed |
|---|---|
| 3 — Muscle memory | Every lockout event was verified with a tested meter or an attempted start button, AND the verification was logged on the work order. |
| 2 — Performed but not logged | Verification happened physically, but the log entry was missing or added later from memory. |
| 1 — Lock hung, no verification | Lock was hung per procedure, but no active verification was performed. |
| 0 — No lockout required | Job did not require lockout. Record separately — do not score on this dimension. |
Your score: _____ (or N/A)
Dimension 3 — Live Data Capture
Observed: when did close-out data get recorded?
| Score | What you observed |
|---|---|
| 3 — At the asset | Technician recorded parts consumed, failure codes, readings, and deviations directly on the asset-side tablet/form/clipboard during the work. |
| 2 — At the job site | Recorded right after completing the work, but before leaving the job area. |
| 1 — At the shop | Recorded at end of shift from memory, at the shop computer. |
| 0 — Not recorded | Close-out was "Repaired. RTO." or equivalent empty text. |
Your score: _____
Dimension 4 — Kit Integrity
Observed: did the crew arrive at an asset with a complete kit?
| Score | What you observed |
|---|---|
| 3 — Complete kit | All parts, procedure, and safety items present and correct on arrival. No trips back. |
| 2 — Kit complete after one adjustment | One item had to be fetched or substituted; the rest was in place. |
| 1 — Kit incomplete | Multiple trips back to the crib or multiple substitutions required. |
| 0 — No kit | Crew arrived without a staged kit; parts were gathered during the job. |
Your score: _____
Wrench-time calculation (summary)
From the field-audit timestamped log:
- Total paid labor hours (crew × shift + OT): _______
- Total on-asset hours (Σ minutes × mechanics ÷ 60 for rows marked ✓): _______
- Wrench time %: (on-asset ÷ paid) × 100 = _______%
Your tier:
- Below 35%: Tier 1 — trouble
- 35-55%: Tier 2 — recovering
- 55-65%: Tier 3 — decent
- Above 65%: Tier 4 — world class
Quarterly trend
| Quarter | Date | Crew | Wrench Time | Briefing | Lockout | Live Data | Kit | Notes |
|---|---|---|---|---|---|---|---|---|
| Baseline | ||||||||
| Q1 | ||||||||
| Q2 | ||||||||
| Q3 | ||||||||
| Q4 |
What the scores tell you
If wrench time moved but the rubric dimensions didn't: measurement error, or a short-term adjustment that won't hold.
If rubric dimensions improved but wrench time didn't: the execution-stage installations are working, but an upstream stage (plan, schedule, identify) is still eating the gain. Go back to Chapters 5-7 and audit the upstream.
If both moved: the cycle is reintegrating. Expect the next quarter to move again. Keep going.
If neither moved: the installations are announced but not installed. Walk the floor.
From Fix the System by Ivan Getov. Companion to Chapter 8: Execute. getov.xyz/toolkit/fix-the-system/ch08/wrench-time-audit. Free. No email required.