Book companion resource · Worksheet

Inspection Route Audit Worksheet

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Audit active inspection routes, code missed work, and verify the findings pipeline before compliance numbers count.

Companion to: Fix the System, Chapter 20. Who uses it: the maintenance manager, reliability engineer, planner, and route owner. When to use: at the start of the Inspection Compliance Recovery playbook, then monthly until route compliance stabilizes.

Plant: _______________________ Date: _______________________ Reviewed by: _______________________

PART 1 — Route Validity Audit

Complete one row per active route. Answer all four validation questions. Any "No" means the route needs corrective action before its compliance numbers count.

All Assets Active?	Frequency Appropriate?	Duration Accurate?	Findings → WO within 24h?
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No

Guidance:

All Assets Active? — Cross-check every stop against CMMS active asset list. Any decommissioned or relocated asset is a guaranteed miss. Delete it from the route immediately.
Frequency Appropriate? — Does the interval match the failure mode? Lube routes: weekly or monthly based on OEM. Vibration routes: monthly or bi-monthly. Visual rounds: daily to weekly. If unknown, default to OEM recommendation until condition data exists.
Duration Accurate? — Compare logged completion times over last 8 weeks against the scheduled time block. If average actual time exceeds scheduled time by more than 10%, the route is overfull.
Findings → WO within 24h? — Review last 10 findings from this route. Were WOs generated or no-action decisions documented within 24 hours? If not, the pipeline is broken.

PART 2 — Miss Coding Log (Last 8 Weeks)

Pull all flagged misses from the CMMS. Assign one primary code per miss. Tally codes at the bottom.

Codes:

IA — Invalid asset (decommissioned, relocated, never commissioned)
DF — Documentation failure (completed but not logged correctly)
TN — Time not available (crew pulled, no coverage)
FN — Finding logged, no action taken (route abandoned due to findings pipeline failure)
DS — Deliberately skipped

Date	Route	Miss Code	Notes / Context	Corrective Action

Code Tally:

Code	Count	% of Total Misses
IA — Invalid asset
DF — Documentation failure
TN — Time not available
FN — Finding no action
DS — Deliberately skipped
Total misses		100%

Interpretation:

IA + DF together above 40%: Route management failure. Fix before any accountability conversation.
TN above 25%: Resource coverage problem. Review labor plan and break-in frequency (see Ch18 Playbook 4).
FN above 15%: Findings pipeline is broken. Technicians have learned that logging findings has no value.
DS above 20%: Crew engagement or consequence gap. Investigate before attributing to supervision failure.

PART 3 — 90-Day Compliance Tracking

Track weekly route completion across all routes. One row per week. Calculate compliance at the bottom.

Week	Routes Scheduled	Routes Completed	Misses	Primary Miss Code(s)	% Compliance
Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10
Week 11
Week 12
Week 13

Formula: % Compliance = Routes Completed ÷ Routes Scheduled × 100

Benchmarks:

Below 80%: Program not delivering value. Audit routes immediately.
80–89%: Recovering. Identify remaining top miss codes and address in sequence.
90–94%: Top quartile. Focus on findings pipeline quality.
95%+: World-class. Maintain and audit route validity annually.

PART 4 — Findings Pipeline Audit

For each route, verify the findings pipeline is operational. Review last 10 findings per route.

Route	Finding Date	Finding Description	WO Generated?	Days to WO / No-Action Decision	Action Taken
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No
			☐ Yes ☐ No

Findings Pipeline Summary:

Total findings reviewed: _______
WOs generated within 24h: _______ (___%)
No-action documented within 24h: _______ (___%)
No action, no documentation: _______ (___%) ← this number must be zero

If findings without documentation exceed 0%: Identify who owns the triage step and set a 24-hour response standard. Escalation path: planner reviews finding same day, routes to reliability engineer if no WO decision by end of shift.

From Fix the System by Ivan Getov. Companion to Chapter 20: Playbook 6 — Inspection Compliance Recovery. getov.xyz/toolkit/fix-the-system/ch20/inspection-route-audit. Free. No email required.

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