Manufacturing Prompt Templates Collection

Create an optimized production schedule for {product_line} with {production_capacity} capacity targeting {demand_forecast}:

**SITUATION:** You need to develop an efficient production schedule that maximizes throughput, minimizes waste, and ensures on-time delivery while maintaining quality standards and resource optimization.

**TASK:** Design a comprehensive production plan that balances demand requirements with available resources, identifies bottlenecks, and provides contingency strategies.

**ACTION:** Structure your production schedule using proven manufacturing frameworks:

**PRODUCTION OVERVIEW**
- **Product Line:** {product_line}
- **Planning Period:** {planning_period}
- **Production Capacity:** {production_capacity}
- **Demand Forecast:** {demand_forecast}
- **Quality Standards:** {quality_standards}
- **Delivery Timeline:** {delivery_timeline}

**CAPACITY ANALYSIS**
- **Production Capacity:** {production_capacity}
- **Quality Requirements:** {quality_standards}
- **Delivery Timeline:** {delivery_timeline}

**DEMAND PLANNING**
- **Demand Forecast:** {demand_forecast}
- **Planning Period:** {planning_period}
- **Product Line Focus:** {product_line}

**PRODUCTION SCHEDULE FRAMEWORK**

**Schedule Structure for {planning_period}:**
- **Product Line Focus:** {product_line}
- **Production Capacity Allocation:** {production_capacity}
- **Quality Control Integration:** {quality_standards}
- **Resource Management:** {resource_constraints}
- **Delivery Coordination:** {delivery_timeline}

**BOTTLENECK ANALYSIS & OPTIMIZATION**
- **Production Capacity Analysis:** {production_capacity}
- **Quality Integration:** {quality_standards}
- **Delivery Coordination:** {delivery_timeline}

**RESOURCE OPTIMIZATION**
- **Product Line Efficiency:** {product_line}
- **Capacity Management:** {production_capacity}
- **Quality Implementation:** {quality_standards}

**QUALITY INTEGRATION**
- **Quality Standards Implementation:** {quality_standards}
- **Product Line Quality Requirements:** {product_line}
- **Facility Quality Controls:** {facility_type}

**CONTINGENCY PLANNING**
- **Resource Constraint Mitigation:** {resource_constraints}
- **Delivery Timeline Flexibility:** {delivery_timeline}
- **Production Capacity Backup Plans:** {production_capacity}

**PERFORMANCE MONITORING**
- **Planning Period Reviews:** {planning_period}
- **Quality Standards Compliance:** {quality_standards}
- **Delivery Performance Tracking:** {delivery_timeline}

**RESULT:** Ensure your production schedule demonstrates:

**Operational Excellence:**
- Optimized {production_capacity} utilization for {product_line}
- {quality_standards} compliance throughout {planning_period}
- Effective {resource_constraints} management
- On-time delivery per {delivery_timeline}

**Strategic Alignment:**
- {facility_type} optimization for maximum efficiency
- Scalable framework for {demand_forecast} variations
- Integrated approach to quality and delivery requirements
- Data-driven decision making for continuous improvement

Create strategic capacity planning framework for {planning_horizon} with {demand_growth} growth projection:

**SITUATION:** You need to develop a comprehensive capacity planning strategy that aligns production capabilities with market demand, optimizes resource utilization, and supports sustainable business growth while maintaining operational efficiency.

**TASK:** Design a strategic capacity plan that balances current operations with future growth requirements, identifies capacity gaps, and provides actionable investment recommendations.

**ACTION:** Structure your capacity planning framework using proven strategic planning methodologies:

**PLANNING OVERVIEW**
- **Planning Horizon:** {planning_horizon}
- **Demand Growth:** {demand_growth}
- **Current Capacity:** {current_capacity}
- **Investment Budget:** {investment_budget}
- **Market Segments:** {market_segments}
- **Growth Targets:** {growth_targets}

**DEMAND ANALYSIS & FORECASTING**

**Market Analysis:**
- Analyze {market_segments} demand patterns over {planning_horizon}
- Project {demand_growth} impact on capacity requirements
- Identify seasonal variations and peak demand periods
- Assess competitive landscape and market share opportunities

**Capacity Requirements:**
- Calculate required capacity to meet {growth_targets}
- Determine gap between {current_capacity} and future needs
- Evaluate scalability requirements for {market_segments}
- Plan for demand volatility and uncertainty scenarios

**CURRENT CAPACITY ASSESSMENT**

**Production Capacity Analysis:**
- Current utilization: 85% of {current_capacity}
- Theoretical vs. practical capacity evaluation
- Bottleneck identification and constraint analysis
- Equipment effectiveness and availability assessment

**Resource Capacity Evaluation:**
1. **Equipment Capacity**
   - Machine utilization rates and throughput analysis
   - Technology capabilities and upgrade requirements
   - Maintenance impact on available capacity
   - Automation opportunities for capacity expansion

2. **Workforce Capacity**
   - Current staffing levels and skill distribution
   - Productivity metrics and improvement potential
   - Training requirements for capacity expansion
   - Labor availability and recruitment challenges

3. **Facility Capacity**
   - Floor space utilization and layout optimization
   - Storage and material handling capacity
   - Utility infrastructure and expansion potential
   - Environmental and regulatory constraints

**CAPACITY GAP ANALYSIS**

**Gap Identification:**
- Short-term gap (Year 1): Based on {demand_growth} projections
- Medium-term gap (Years 2-3): Aligned with {growth_targets}
- Long-term gap ({planning_horizon}): Strategic market expansion
- Peak demand scenarios and surge capacity requirements

**Constraint Analysis:**
1. **Primary Constraints**
   - Equipment bottlenecks limiting {current_capacity}
   - Workforce limitations affecting productivity
   - Facility space restrictions for expansion
   - Financial constraints within {investment_budget}

2. **Secondary Constraints**
   - Supply chain limitations and supplier capacity
   - Quality requirements and compliance standards
   - Regulatory approvals and environmental permits
   - Technology limitations and upgrade requirements

**CAPACITY EXPANSION OPTIONS**

**Option 1: Equipment Expansion**
- Investment: 40% of {investment_budget}
- Capacity increase: 25% above {current_capacity}
- Implementation: 6-12 months
- ROI: 18-22% over 5 years
- Risk: Medium - technology and integration risks

**Option 2: Facility Expansion**
- Investment: 60% of {investment_budget}
- Capacity increase: 50% above {current_capacity}
- Implementation: 12-18 months
- ROI: 15-20% over 7 years
- Risk: High - construction and regulatory risks

**Option 3: Workforce Expansion**
- Investment: 20% of {investment_budget}
- Capacity increase: 15% above {current_capacity}
- Implementation: 3-6 months
- ROI: 25-30% over 3 years
- Risk: Low - recruitment and training risks

**Option 4: Process Optimization**
- Investment: 15% of {investment_budget}
- Capacity increase: 10% above {current_capacity}
- Implementation: 2-4 months
- ROI: 35-40% over 2 years
- Risk: Low - implementation and change management

**Option 5: Outsourcing/Partnerships**
- Investment: Variable based on volume
- Capacity access: Flexible scaling with demand
- Implementation: 1-3 months
- Cost: Premium pricing but flexible
- Risk: Medium - quality and control risks

**IMPLEMENTATION ROADMAP**

**Phase 1: Foundation (0-6 months)**
- Process optimization initiatives for immediate {current_capacity} gains
- Workforce training and productivity improvements
- Equipment maintenance and reliability enhancements
- Quick wins targeting 5-10% capacity increase

**Phase 2: Expansion (6-18 months)**
- Equipment additions based on {investment_budget} allocation
- Facility modifications and layout optimization
- Workforce expansion aligned with {growth_targets}
- Technology upgrades and automation implementation

**Phase 3: Strategic Growth (18+ months)**
- Major facility expansion or new site development
- Advanced technology integration and digitalization
- Market expansion into new {market_segments}
- Partnership development and supply chain optimization

**PERFORMANCE MONITORING**

**Key Performance Indicators:**
- Capacity Utilization: Target 90% of available capacity
- Throughput: Achieve {growth_targets} production levels
- Efficiency: 15% improvement over {planning_horizon}
- Cost per Unit: Reduce by 10% through scale economies

**Monitoring Framework:**
- Monthly capacity utilization and bottleneck analysis
- Quarterly performance reviews against {growth_targets}
- Annual strategic assessment of {market_segments} evolution
- Continuous improvement initiatives and best practice sharing

**RISK MANAGEMENT**

**Capacity Risks:**
- Demand volatility exceeding {demand_growth} projections
- Technology obsolescence affecting {current_capacity}
- Competitive pressure in target {market_segments}
- Economic downturns impacting {investment_budget}

**Mitigation Strategies:**
- Flexible capacity solutions and modular expansion
- Diversification across multiple {market_segments}
- Contingency planning for demand scenarios
- Insurance coverage and financial risk management

**RESULT:** Ensure your capacity planning framework demonstrates:

**Strategic Alignment:**
- Clear alignment with {growth_targets} and market opportunities in {market_segments}
- Balanced approach to growth and risk management within {investment_budget}
- Optimized resource allocation across {planning_horizon}
- Scalable capacity solutions supporting {demand_growth}

**Operational Excellence:**
- Efficient utilization of {current_capacity} and expansion investments
- Flexible response to demand variations and market changes
- Continuous improvement and performance monitoring
- Cost-effective capacity expansion and resource management

**Competitive Advantage:**
- Market-responsive capacity planning for {market_segments}
- Technology-enabled optimization and automation
- Strategic positioning for {growth_targets} achievement
- Sustainable competitive advantage through operational excellence

Create comprehensive lean manufacturing implementation plan for {current_state} targeting {target_improvements}:

**SITUATION:** You need to transform your manufacturing operations using lean principles to eliminate waste, improve efficiency, reduce costs, and create a culture of continuous improvement that delivers sustainable competitive advantage.

**TASK:** Design a systematic lean transformation that addresses all eight wastes, implements lean tools and techniques, and establishes a continuous improvement culture throughout the organization.

**ACTION:** Structure your lean implementation using proven lean transformation methodologies:

**TRANSFORMATION OVERVIEW**
- **Current State:** {current_state}
- **Target Improvements:** {target_improvements}
- **Facility Size:** {facility_size}
- **Implementation Timeline:** {implementation_timeline}
- **Transformation Budget:** {transformation_budget}
- **Employee Count:** {employee_count}

**CURRENT STATE ASSESSMENT**

**Operational Assessment:**
- Current manufacturing approach: {current_state}
- Facility scale and complexity: {facility_size}
- Workforce engagement level: {employee_count} employees
- Improvement opportunities: {target_improvements}

**Waste Identification (8 Wastes of Lean):**

**1. Overproduction:**
- Current state analysis reveals excess production beyond customer demand
- Impact: Increased inventory costs, storage requirements, and cash flow issues
- Root causes: Push-based scheduling, large batch sizes, unclear demand signals
- Improvement opportunity: Implement pull systems and demand-driven production

**2. Waiting:**
- Equipment and operator idle time due to bottlenecks and imbalanced flow
- Impact: Reduced productivity, increased lead times, higher labor costs
- Root causes: Unbalanced workstations, equipment downtime, material shortages
- Improvement opportunity: Line balancing, preventive maintenance, flow optimization

**3. Transportation:**
- Excessive movement of materials and products between operations
- Impact: Increased handling costs, damage risk, extended lead times
- Root causes: Poor layout design, centralized storage, batch processing
- Improvement opportunity: Cellular manufacturing, point-of-use storage

**4. Over-processing:**
- Work performed beyond customer requirements or specifications
- Impact: Increased costs, longer cycle times, resource waste
- Root causes: Unclear specifications, gold-plating, outdated procedures
- Improvement opportunity: Value analysis, standardization, customer focus

**5. Inventory:**
- Excess raw materials, work-in-process, and finished goods
- Impact: Tied-up capital, storage costs, obsolescence risk
- Root causes: Large batch sizes, poor forecasting, safety stock mentality
- Improvement opportunity: Just-in-time delivery, kanban systems

**6. Motion:**
- Unnecessary movement of people and equipment during operations
- Impact: Increased fatigue, safety risks, reduced productivity
- Root causes: Poor workplace organization, inadequate tool placement
- Improvement opportunity: 5S implementation, ergonomic improvements

**7. Defects:**
- Products not meeting quality standards requiring rework or scrap
- Impact: Increased costs, customer dissatisfaction, reduced capacity
- Root causes: Process variation, inadequate training, poor quality systems
- Improvement opportunity: Error-proofing, statistical process control

**8. Underutilized Talent:**
- Not fully engaging employee skills, creativity, and improvement ideas
- Impact: Missed opportunities, low engagement, limited innovation
- Root causes: Top-down culture, lack of empowerment, poor communication
- Improvement opportunity: Employee involvement, suggestion systems

**VALUE STREAM MAPPING**

**Current State Value Stream:**
- Map complete process flow from customer order to delivery
- Document current lead times, cycle times, and inventory levels
- Identify value-added vs. non-value-added activities
- Calculate current value stream efficiency baseline

**Value Stream Analysis:**
- Determine customer demand patterns and takt time requirements
- Analyze cycle times at each process step
- Evaluate changeover times and setup requirements
- Assess batch sizes and inventory accumulation points
- Identify bottlenecks and constraint operations

**Future State Value Stream:**
- Design ideal flow with {target_improvements} objectives
- Eliminate non-value-added activities and waste
- Implement continuous flow where possible
- Establish pull systems and demand-driven production
- Target 50% reduction in lead time and 30% efficiency improvement

**LEAN IMPLEMENTATION ROADMAP**

**Phase 1: Foundation Building (Months 1-3)**
*Budget allocation: 25% of {transformation_budget}*

**Leadership Development:**
- Executive and management lean leadership training program
- Change management strategy development and communication
- Lean champion identification and training across {facility_size}
- Success metrics establishment aligned with {target_improvements}

**5S Implementation:**
- **Sort (Seiri):** Remove unnecessary items from all work areas
- **Set in Order (Seiton):** Organize tools and materials for efficiency
- **Shine (Seiso):** Clean and maintain workplace standards
- **Standardize (Seiketsu):** Establish consistent procedures
- **Sustain (Shitsuke):** Create audit systems and continuous improvement

**Phase 2: Flow Creation (Months 4-8)**
*Budget allocation: 35% of {transformation_budget}*

**Cellular Manufacturing:**
- Design manufacturing cells based on product families
- Optimize layout for {facility_size} constraints and flow
- Standardize work procedures and cycle times
- Cross-train {employee_count} workforce for flexibility

**Pull System Implementation:**
- Implement kanban systems for material flow control
- Design supermarkets for component storage and replenishment
- Establish FIFO (First-In-First-Out) lanes for work-in-process
- Create visual management systems for production control

**Phase 3: Continuous Flow (Months 9-12)**
*Budget allocation: 30% of {transformation_budget}*

**Single-Piece Flow:**
- Reduce batch sizes to approach single-piece flow
- Implement SMED (Single Minute Exchange of Dies) for quick changeovers
- Balance production lines for smooth flow
- Install poka-yoke (error-proofing) devices

**Total Productive Maintenance (TPM):**
- Train operators in autonomous maintenance practices
- Establish planned maintenance schedules and procedures
- Implement quality maintenance to prevent defects
- Measure and improve Overall Equipment Effectiveness (OEE)

**Phase 4: Perfection Pursuit (Months 13+ within {implementation_timeline})**
*Budget allocation: 10% of {transformation_budget}*

**Continuous Improvement Culture:**
- Conduct regular kaizen events for targeted improvements
- Implement employee suggestion systems and recognition
- Provide problem-solving training for all {employee_count} employees
- Establish improvement tracking and celebration systems

**LEAN TOOLS IMPLEMENTATION**

**Value Stream Mapping:**
- Map current state processes and identify improvement opportunities
- Design future state with {target_improvements} objectives
- Create detailed implementation plan with timelines and responsibilities
- Track progress through regular reviews and updates

**5S Workplace Organization:**
- Implement across all areas of {facility_size} systematically
- Provide comprehensive training for all {employee_count} employees
- Establish audit systems and scoring mechanisms
- Create sustainability plans with ongoing reinforcement

**Kanban Pull System:**
- Design kanban cards and containers for material flow
- Calculate kanban quantities based on demand and lead times
- Implement pilot areas before full {facility_size} rollout
- Monitor performance and adjust system parameters

**Single Minute Exchange of Dies (SMED):**
- Analyze current changeover processes and times
- Separate external and internal setup activities
- Implement improvements to reduce changeover times by 75%
- Target single-digit minute changeovers where possible

**Poka-Yoke (Error Proofing):**
- Analyze error modes and failure points in processes
- Design prevention and detection methods
- Prioritize implementation based on impact and feasibility
- Measure effectiveness through defect reduction

**TRAINING & DEVELOPMENT**

**Lean Training Curriculum:**
- **Leadership Training:** Executive lean leadership development program
- **Champion Training:** Intensive lean tools and facilitation training
- **Employee Training:** Basic lean principles for all {employee_count} staff
- **Supplier Training:** Extend lean principles to key suppliers

**Competency Development:**
- Lean principles and philosophy understanding
- Problem-solving methodologies (A3, 8D, 5 Why)
- Statistical tools and data analysis techniques
- Change management and communication skills

**MEASUREMENT & MONITORING**

**Key Performance Indicators:**
- **Operational KPIs:** Productivity, cycle time, throughput, OEE
- **Quality KPIs:** Defect rates, first-pass yield, customer satisfaction
- **Cost KPIs:** Cost per unit, waste reduction, inventory turns
- **Delivery KPIs:** On-time delivery, lead time, schedule adherence

**Measurement System:**
- Daily visual management boards and metrics tracking
- Weekly team reviews and problem-solving sessions
- Monthly management reviews and trend analysis
- Quarterly business reviews and strategic alignment

**CHANGE MANAGEMENT**

**Cultural Transformation:**
- Assess current culture readiness for lean transformation
- Define target culture emphasizing continuous improvement
- Develop change strategy appropriate for {employee_count} workforce
- Manage resistance through communication and involvement

**Communication Plan:**
- Map stakeholders across all levels of {facility_size} organization
- Establish multiple communication channels and feedback loops
- Create consistent messaging framework about {target_improvements}
- Implement regular feedback mechanisms and two-way communication

**SUSTAINABILITY PLAN**

**Continuous Improvement System:**
- Establish kaizen culture with regular improvement events
- Create structured improvement process and idea management
- Implement recognition and reward systems for contributions
- Develop knowledge management and best practice sharing

**Performance Monitoring:**
- Monthly operational reviews and metric tracking
- Quarterly assessments of {target_improvements} progress
- Annual evaluations and strategic planning updates
- Benchmarking against industry standards and best practices

**RESULT:** Ensure your lean implementation demonstrates:

**Operational Excellence:**
- Systematic elimination of all eight wastes across {facility_size}
- Achievement of {target_improvements} through optimized value streams
- Reduced lead times and inventory levels within {implementation_timeline}
- Enhanced quality and customer satisfaction metrics

**Cultural Transformation:**
- Engaged {employee_count} workforce committed to continuous improvement
- Problem-solving capabilities developed at all organizational levels
- Sustainable lean practices and behaviors embedded in daily operations
- Innovation and creativity in process improvement initiatives

**Business Impact:**
- Measurable improvements in cost, quality, delivery, and safety
- ROI achievement within {transformation_budget} parameters
- Increased competitiveness and market responsiveness
- Foundation for long-term operational excellence and growth

**Strategic Alignment:**
- Lean transformation supporting {target_improvements} objectives
- Scalable implementation approach suitable for {facility_size}
- Timeline execution within {implementation_timeline} constraints
- Budget management within {transformation_budget} allocation
- Workforce development across all {employee_count} employees
- Cultural change from {current_state} to lean excellence

Create comprehensive quality inspection protocol for {product_type} following {quality_standards}:

**SITUATION:** You need to establish a robust quality inspection system that ensures product conformity, reduces defects, maintains customer satisfaction, and meets regulatory compliance requirements.

**TASK:** Design a detailed inspection protocol that covers all critical quality points, provides clear acceptance criteria, and ensures consistent quality outcomes.

**ACTION:** Structure your quality inspection protocol using proven QMS frameworks:

**INSPECTION OVERVIEW**
- **Product/Component:** {product_type}
- **Quality Standards:** {quality_standards}
- **Inspection Frequency:** {inspection_frequency}
- **Sample Size:** {sample_size}
- **Test Methods:** {test_methods}
- **Acceptance Criteria:** {acceptance_criteria}

**QUALITY SPECIFICATIONS**

**Product Requirements:**
- Define critical characteristics for {product_type}
- Establish dimensional tolerances and specifications
- Document material properties and performance requirements
- Specify functional and aesthetic quality attributes

**Standards Compliance:**
- Implement {quality_standards} requirements throughout process
- Ensure regulatory compliance and customer specifications
- Maintain certification requirements and audit readiness
- Document compliance evidence and verification methods

**INSPECTION PROCEDURES**

**Pre-Inspection Setup:**
- Calibrate all measuring equipment per {quality_standards} requirements
- Verify environmental conditions meet {product_type} specifications
- Confirm inspector qualifications and training currency
- Prepare inspection documentation and record-keeping systems

**Incoming Material Inspection:**
**Inspection Points:**
- Visual inspection for obvious defects and damage
- Dimensional verification using appropriate {test_methods}
- Material certification review and supplier documentation
- Statistical sampling per {sample_size} requirements

**Sampling Procedure:**
- Apply {sample_size} methodology based on lot size and risk
- Use random sampling methods to ensure representative selection
- Implement proper sample identification and traceability
- Follow handling procedures to prevent contamination or damage

**In-Process Inspection:**
**Control Points:**
- **First Article Inspection:** Complete dimensional and functional verification
  - Check: All critical characteristics per {acceptance_criteria}
  - Frequency: {inspection_frequency} or per production run
  - Method: {test_methods} as specified in work instructions
  - Record: Document results in inspection records

- **Process Monitoring:** Ongoing verification during production
  - Check: Key process parameters and product characteristics
  - Frequency: Based on {inspection_frequency} requirements
  - Method: Statistical process control and {test_methods}
  - Record: Control charts and process capability data

**Final Product Inspection:**
**Comprehensive Checks:**
- Functional testing per {product_type} specifications
- Performance verification against {acceptance_criteria}
- Appearance inspection for cosmetic and finish requirements
- Packaging verification and labeling compliance

**MEASUREMENT & TESTING**

**Required Equipment:**
- Measuring tools appropriate for {product_type} characteristics
- Test equipment calibrated per {quality_standards} requirements
- Calibration schedule maintained with traceability records
- Accuracy requirements meeting {acceptance_criteria} specifications

**Testing Procedures:**
1. **Dimensional Verification**
   - Procedure: Use {test_methods} for critical dimensions
   - Acceptance Range: Per {acceptance_criteria} specifications
   - Frequency: According to {inspection_frequency} schedule
   - Documentation: Record all measurements and deviations

2. **Functional Testing**
   - Procedure: Verify {product_type} performance requirements
   - Acceptance Range: Meet all {acceptance_criteria} parameters
   - Frequency: Per {inspection_frequency} and {sample_size} requirements
   - Documentation: Complete test reports and certificates

**ACCEPTANCE CRITERIA**

**Pass/Fail Criteria:**
- **Critical Defects:** Zero tolerance per {quality_standards}
- **Major Defects:** AQL 1.0 or customer-specified levels
- **Minor Defects:** AQL 2.5 or per {acceptance_criteria}

**Statistical Control:**
- Control charts for key {product_type} characteristics
- Process capability Cpk ≥ 1.33 for critical features
- First Pass Yield ≥ 95% target performance
- Defect rate ≤ 100 PPM for critical characteristics

**DOCUMENTATION & RECORDS**

**Inspection Records:**
- Inspection checklists specific to {product_type} requirements
- Measurement data recording per {test_methods} procedures
- Non-conformance reports with disposition and corrective actions
- Statistical data and trend analysis for continuous improvement

**Traceability Requirements:**
- Lot identification and tracking throughout production
- Material traceability from supplier to finished {product_type}
- Process records linking inspection results to production batches
- Customer-specific documentation per {quality_standards}

**NON-CONFORMANCE MANAGEMENT**

**Identification & Segregation:**
- Immediate identification and segregation of non-conforming {product_type}
- Clear marking and containment to prevent inadvertent use
- Investigation process to determine root cause and extent
- Communication to relevant stakeholders and customers

**Disposition Options:**
- **Rework:** Return to production for correction per {acceptance_criteria}
- **Repair:** Engineering authorization for deviation acceptance
- **Scrap:** Disposal when product cannot meet {quality_standards}
- **Use-As-Is:** Customer concession for minor deviations

**CONTINUOUS IMPROVEMENT**

**Data Analysis:**
- Trend analysis of {product_type} quality performance
- Pareto analysis to prioritize improvement opportunities
- Root cause analysis using structured problem-solving methods
- Process improvement initiatives based on data insights

**Performance Metrics:**
- Quality KPIs aligned with {quality_standards} objectives
- Customer satisfaction measurement and feedback analysis
- Cost of quality tracking including prevention, appraisal, and failure costs
- Supplier performance monitoring and improvement programs

**TRAINING & COMPETENCY**

**Inspector Training:**
- Initial training on {product_type} specifications and {test_methods}
- Competency assessment and certification per {quality_standards}
- Ongoing training for new products and procedure updates
- Annual recertification and skill maintenance programs

**RESULT:** Ensure your quality inspection protocol demonstrates:

**Quality Assurance:**
- Comprehensive coverage of all critical {product_type} quality points
- Clear, measurable {acceptance_criteria} for consistent decisions
- Consistent {test_methods} and inspection procedures
- Robust documentation and traceability systems

**Compliance & Standards:**
- Full alignment with {quality_standards} requirements
- Regulatory compliance and customer specifications
- Statistical process control implementation using {sample_size} methodology
- Continuous improvement integration with {inspection_frequency} reviews

**Operational Excellence:**
- Efficient inspection workflows optimized for {product_type}
- Trained and competent inspection personnel using {test_methods}
- Effective non-conformance management per {acceptance_criteria}
- Data-driven quality decision making with {inspection_frequency} monitoring

**System Integration:**
- {Product_type} specifications clearly defined and measurable
- {Quality_standards} compliance verified through systematic inspection
- {Test_methods} validated and consistently applied
- {Sample_size} statistically appropriate for risk and volume
- {Inspection_frequency} optimized for quality assurance and efficiency
- {Acceptance_criteria} aligned with customer and regulatory requirements

Conduct comprehensive defect analysis for {defect_type} with {occurrence_frequency} frequency:

**SITUATION:** You need to systematically investigate a quality defect, identify root causes, implement effective corrective actions, and establish preventive measures to ensure the issue does not recur.

**TASK:** Perform thorough defect analysis using structured problem-solving methodologies to eliminate the defect and improve overall process capability.

**ACTION:** Structure your defect analysis using proven quality investigation frameworks:

**DEFECT OVERVIEW**
- **Defect Type:** {defect_type}
- **Occurrence Frequency:** {occurrence_frequency}
- **Product Line:** {product_line}
- **Quality Standards:** {quality_standards}
- **Investigation Method:** {investigation_method}
- **Corrective Timeline:** {corrective_timeline}

**PROBLEM DEFINITION**

**Defect Description:**
- **What:** Specific {defect_type} characteristics and manifestation
- **Where:** Location in {product_line} process or final product
- **When:** Timing pattern related to {occurrence_frequency}
- **How Many:** Quantity and rate of defect occurrence
- **Impact:** Effect on quality, cost, delivery, and customer satisfaction

**Problem Statement:**
Clear, specific statement describing the {defect_type} issue, its impact on {product_line}, and the urgency based on {occurrence_frequency} and {quality_standards} requirements.

**Scope Definition:**
- **In Scope:** {Defect_type} investigation within {product_line} operations
- **Out of Scope:** Other quality issues not related to current {defect_type}
- **Boundaries:** Analysis limited to {corrective_timeline} and available resources

**DATA COLLECTION & ANALYSIS**

**Defect Data:**
- Document total defects and calculate defect rate for {product_line}
- Identify first occurrence and establish timeline pattern
- Analyze {occurrence_frequency} patterns and trends
- Correlate defects with production variables and conditions

**Process Data:**
- Collect process parameters during {defect_type} occurrences
- Review control chart data and statistical process control
- Calculate process capability (Cpk) for affected characteristics
- Perform statistical analysis to identify significant factors

**Product Data:**
- Identify affected lot numbers and production dates
- Document shift information and personnel involved
- Record equipment used during defect occurrence
- Trace material batches and supplier information

**CONTAINMENT ACTIONS**

**Immediate Containment:**
- Implement immediate actions to prevent further {defect_type} occurrence
- Assign responsible person and establish clear accountability
- Set implementation date within {corrective_timeline}
- Verify containment effectiveness through inspection and testing

**Product Disposition:**
- Quarantine affected inventory and prevent shipment
- Evaluate existing inventory for {defect_type} presence
- Notify customers per {quality_standards} requirements
- Assess recall considerations based on defect severity and impact

**ROOT CAUSE ANALYSIS**

**5 Why Analysis using {investigation_method}:**
1. **Why did {defect_type} occur?**
   Answer: Investigate immediate cause related to {product_line} process

2. **Why did the immediate cause happen?**
   Answer: Examine process controls and procedures

3. **Why were controls insufficient?**
   Answer: Analyze system design and implementation

4. **Why was the system inadequate?**
   Answer: Review organizational factors and resources

5. **Why were organizational factors not addressed?**
   Answer: Identify root cause requiring systemic change

**Fishbone Analysis (6M Categories):**

**Man (People):**
- Training adequacy for {product_line} operations
- Skill gaps in {defect_type} prevention
- Communication effectiveness across shifts
- Procedural compliance and understanding

**Machine (Equipment):**
- Equipment condition and maintenance status
- Calibration accuracy and frequency
- Machine capability for {quality_standards}
- Preventive maintenance effectiveness

**Material (Raw Materials):**
- Incoming material quality and specifications
- Supplier performance and consistency
- Storage conditions and material handling
- Material traceability and lot control

**Method (Process):**
- Process design robustness for {defect_type} prevention
- Work instruction clarity and completeness
- Process controls and monitoring systems
- Process validation and capability studies

**Measurement (Inspection):**
- Measurement system accuracy and precision
- Gauge repeatability and reproducibility
- Inspection frequency and coverage
- Detection capability for {defect_type}

**Mother Nature (Environment):**
- Environmental conditions affecting {product_line}
- Temperature and humidity control
- Cleanliness and contamination control
- Workspace layout and ergonomics

**ROOT CAUSE VERIFICATION**

**Hypothesis Testing:**
- Develop primary hypothesis based on {investigation_method} findings
- Design test method appropriate for {defect_type} verification
- Execute tests and collect objective evidence
- Draw conclusions and validate root cause identification

**Data Validation:**
- Gather supporting evidence from multiple sources
- Ensure statistical significance of findings
- Test reproducibility of {defect_type} under controlled conditions
- Conduct peer review with subject matter experts

**CORRECTIVE ACTIONS**

**Immediate Corrective Actions (within {corrective_timeline}):**
1. **Containment Action**
   - Responsible: Quality/Production Manager
   - Target Date: Immediate (within 24 hours)
   - Resources Required: Inspection team and quarantine area
   - Success Criteria: 100% containment of {defect_type}

2. **Process Adjustment**
   - Responsible: Process Engineer
   - Target Date: Within {corrective_timeline}
   - Resources Required: Engineering support and equipment
   - Success Criteria: Elimination of {defect_type} in new production

**Long-term Corrective Actions:**
1. **System Enhancement**
   - Responsible: Quality Manager
   - Target Date: Extended beyond {corrective_timeline}
   - Investment Required: Based on {quality_standards} requirements
   - Expected Benefit: Permanent {defect_type} prevention

**PREVENTIVE ACTIONS**

**Process Improvements:**
- Implement process changes to prevent {defect_type} recurrence
- Enhance control systems and monitoring capabilities
- Identify automation opportunities for error reduction
- Design error-proofing (poka-yoke) solutions

**System Improvements:**
- Develop training programs addressing {defect_type} prevention
- Update procedures and work instructions
- Modify quality system per {quality_standards}
- Establish supplier requirements and controls

**IMPLEMENTATION PLAN**

**Phase 1: Immediate Actions (within {corrective_timeline})**
- Priority actions for {defect_type} containment and correction
- Resource allocation including personnel and equipment
- Key milestones for containment and immediate fixes
- Success metrics aligned with {quality_standards}

**Phase 2: Short-term Actions (1-3 months)**
- Process improvements targeting {defect_type} prevention
- System updates and procedure modifications
- Training implementation for {product_line} personnel
- Validation activities to confirm effectiveness

**Phase 3: Long-term Actions (3+ months)**
- Strategic improvements for sustainable {defect_type} prevention
- Technology upgrades and automation implementation
- Culture changes promoting quality awareness
- Continuous monitoring and improvement systems

**VERIFICATION & VALIDATION**

**Effectiveness Verification:**
- Verification method using {investigation_method} principles
- Success criteria based on {defect_type} elimination
- Measurement plan with statistical validation
- Timeline aligned with {corrective_timeline} requirements

**Performance Monitoring:**
- Key metrics tracking {defect_type} occurrence rates
- Monitoring frequency based on {occurrence_frequency} patterns
- Reporting structure for {product_line} quality performance
- Review process ensuring {quality_standards} compliance

**LESSONS LEARNED**

**Key Insights:**
- Process insights specific to {defect_type} prevention
- System insights for {product_line} quality improvement
- Organizational insights for culture enhancement
- Technical insights for {investigation_method} effectiveness

**Best Practices:**
- Investigation methods proven effective for {defect_type}
- Communication strategies for quality issues
- Implementation approaches within {corrective_timeline}
- Monitoring techniques for {occurrence_frequency} tracking

**Knowledge Sharing:**
- Documentation updates for {product_line} procedures
- Training materials addressing {defect_type} prevention
- Standard operating procedure enhancements
- Cross-functional sharing of {investigation_method} learnings

**RESULT:** Ensure your defect analysis demonstrates:

**Systematic Investigation:**
- Thorough data collection and objective analysis of {defect_type}
- Structured root cause identification using {investigation_method}
- Evidence-based conclusions for {product_line} improvement
- Comprehensive documentation meeting {quality_standards}

**Effective Problem Resolution:**
- Targeted corrective actions addressing {defect_type} root causes
- Preventive measures aligned with {corrective_timeline}
- Sustainable solutions reducing {occurrence_frequency}
- Continuous improvement integration across {product_line}

**Organizational Learning:**
- Knowledge capture specific to {defect_type} prevention
- Process and system improvements for {product_line}
- Enhanced problem-solving capabilities using {investigation_method}
- Quality culture advancement supporting {quality_standards}

**Strategic Impact:**
- {Defect_type} elimination improving {product_line} quality
- {Investigation_method} application building analytical capabilities
- {Corrective_timeline} adherence demonstrating responsiveness
- {Quality_standards} compliance ensuring customer satisfaction
- {Occurrence_frequency} reduction through systematic approach
- {Product_line} reliability enhancement through root cause elimination
- Cultural development toward quality excellence

Create comprehensive supplier evaluation framework for {material_category} with {supplier_requirements}:

**SITUATION:** You need to establish a robust supplier evaluation and selection process that ensures reliable partnerships, minimizes supply chain risks, and optimizes cost, quality, and delivery performance.

**TASK:** Design a systematic approach to evaluate, select, and monitor suppliers that aligns with business objectives and supply chain strategy.

**ACTION:** Structure your supplier evaluation framework using proven supply chain methodologies:

**EVALUATION OVERVIEW**
- **Material/Service Category:** {material_category}
- **Supplier Requirements:** {supplier_requirements}
- **Evaluation Criteria:** {evaluation_criteria}
- **Budget Range:** {budget_range}
- **Delivery Requirements:** {delivery_requirements}
- **Quality Expectations:** {quality_expectations}

**SUPPLIER REQUIREMENTS**

**Basic Qualifications:**
- Minimum qualifications specific to {material_category} supply
- Compliance with {supplier_requirements} standards
- Financial stability and business continuity capability
- Technical competency and manufacturing capability

**Performance Standards:**
- Budget alignment within {budget_range} parameters
- Quality standards meeting {quality_expectations}
- Delivery performance per {delivery_requirements}
- Service level commitments and responsiveness

**EVALUATION CRITERIA MATRIX**

**Primary Evaluation Factors:**
- Material category specialization in {material_category}
- Comprehensive assessment using {evaluation_criteria}
- Quality performance meeting {quality_expectations}
- Delivery capability per {delivery_requirements}
- Cost competitiveness within {budget_range}
- Compliance with {supplier_requirements}

**Financial Stability (Weight: 25%)**
1. **Financial Health**
   - Credit rating and financial statement analysis
   - Cash flow stability and debt management
   - Profitability trends and financial ratios
   - Banking relationships and credit history

2. **Business Stability**
   - Years in business and market experience
   - Market position and competitive standing
   - Customer diversification and dependency risk
   - Growth trajectory and business sustainability

**Technical Capabilities (Weight: 30%)**
1. **Manufacturing Capabilities**
   - Equipment technology appropriate for {material_category}
   - Process capabilities and quality systems
   - Capacity utilization and scalability potential
   - Manufacturing flexibility and responsiveness

2. **Innovation & Development**
   - R&D investment and technical expertise
   - Collaboration capability and partnership approach
   - Future technology roadmap and innovation pipeline
   - Continuous improvement culture and practices

**RISK ASSESSMENT**

**Supply Chain Risks:**
1. **Geographic Risks**
   - Political stability and regulatory environment
   - Natural disaster exposure and business continuity
   - Infrastructure reliability and logistics capability
   - Currency fluctuation and economic stability

2. **Operational Risks**
   - Single source dependency and supply concentration
   - Capacity constraints and scalability limitations
   - Quality risks affecting {quality_expectations}
   - Delivery risks impacting {delivery_requirements}

3. **Strategic Risks**
   - Competitive conflicts and market positioning
   - Intellectual property protection and confidentiality
   - Regulatory changes affecting {material_category}
   - Technology obsolescence and innovation gaps

**Risk Mitigation Strategies:**
- Identify primary risks specific to {material_category} supply
- Develop mitigation plans aligned with {supplier_requirements}
- Establish contingency plans within {budget_range} constraints
- Implement monitoring systems for early risk detection

**SUPPLIER ASSESSMENT PROCESS**

**Phase 1: Initial Screening**
- RFI (Request for Information) for {material_category} suppliers
- Basic qualification against {supplier_requirements}
- Preliminary scoring using {evaluation_criteria}
- Shortlist creation based on minimum thresholds

**Phase 2: Detailed Evaluation**
- RFQ (Request for Quote) within {budget_range} parameters
- Technical assessment for {material_category} capabilities
- Financial analysis and stability evaluation
- Reference checks and performance validation

**Phase 3: Site Visits & Audits**
- Facility assessment for {material_category} production
- Process review and capability evaluation
- Quality audit against {quality_expectations}
- Management interviews and cultural fit assessment

**SCORING & SELECTION**

**Scoring Methodology:**
- Weighted scoring using {evaluation_criteria} framework
- Quality (30%): {quality_expectations} compliance
- Delivery (25%): {delivery_requirements} performance
- Cost (20%): {budget_range} competitiveness
- Financial (15%): Stability and sustainability
- Technical (10%): {material_category} expertise

**Selection Decision Matrix:**
| Supplier | Quality | Delivery | Cost | Financial | Technical | Risk | Total |
|----------|---------|----------|------|-----------|-----------|------|-------|
| Supplier A | 85 | 90 | 75 | 80 | 85 | Low | 82 |
| Supplier B | 90 | 85 | 80 | 85 | 80 | Medium | 84 |
| Supplier C | 80 | 95 | 85 | 75 | 90 | Low | 85 |

**IMPLEMENTATION PLAN**

**Supplier Development:**
- Onboarding process for {material_category} suppliers
- Training requirements aligned with {supplier_requirements}
- Integration timeline supporting {delivery_requirements}
- Performance monitoring using {evaluation_criteria}

**Contract Negotiation:**
- Key terms reflecting {quality_expectations} and {delivery_requirements}
- SLAs (Service Level Agreements) within {budget_range}
- Performance metrics based on {evaluation_criteria}
- Review periods for continuous improvement

**ONGOING PERFORMANCE MANAGEMENT**

**Performance Metrics:**
- Quality KPIs aligned with {quality_expectations}
- Delivery KPIs meeting {delivery_requirements}
- Cost KPIs within {budget_range} targets
- Service KPIs supporting {material_category} needs

**Review Process:**
- Monthly reviews of {material_category} performance
- Quarterly business reviews using {evaluation_criteria}
- Annual strategic reviews and relationship assessment
- Continuous improvement initiatives and partnership development

**RESULT:** Ensure your supplier evaluation framework demonstrates:

**Strategic Alignment:**
- Clear alignment with {material_category} supply strategy
- Comprehensive evaluation using {evaluation_criteria}
- Balanced consideration of {quality_expectations}, {delivery_requirements}, and {budget_range}
- Long-term partnership development per {supplier_requirements}

**Risk Management:**
- Thorough risk identification specific to {material_category}
- Effective mitigation strategies within {budget_range}
- Diversified supplier base reducing dependencies
- Continuous monitoring aligned with {evaluation_criteria}

**Operational Excellence:**
- Standardized evaluation processes for {material_category}
- Data-driven decision making using {evaluation_criteria}
- Efficient supplier onboarding meeting {delivery_requirements}
- Performance optimization supporting {quality_expectations}

Create comprehensive workplace safety risk assessment for {workplace_area} addressing {hazard_types}:

**SITUATION:** You need to conduct a thorough safety risk assessment to identify workplace hazards, evaluate risks, implement control measures, and ensure OSHA compliance while protecting worker health and safety.

**TASK:** Develop a systematic risk assessment that identifies all potential hazards, evaluates their risks, and establishes effective control measures and safety protocols.

**ACTION:** Structure your safety risk assessment using proven EHS methodologies:

**ASSESSMENT OVERVIEW**
- **Workplace Area:** {workplace_area}
- **Hazard Types:** {hazard_types}
- **Risk Level:** {risk_level}
- **Employee Count:** {employee_count}
- **Compliance Standards:** {compliance_standards}
- **Assessment Timeline:** {assessment_timeline}

**HAZARD IDENTIFICATION**
- **Workplace Area Analysis:** Comprehensive assessment of {workplace_area}
- **Hazard Types Present:** Systematic identification of {hazard_types}
- **Risk Level Assessment:** Evaluation targeting {risk_level} scenarios
- **Employee Exposure:** Analysis covering {employee_count} workers
- **Compliance Requirements:** Adherence to {compliance_standards}

**RISK EVALUATION MATRIX**

**Risk Assessment Methodology:**
Risk Level = Severity × Probability

**Severity Scale:**
- **1 - Minor:** First aid treatment only
- **2 - Moderate:** Medical treatment required
- **3 - Major:** Lost time injury/illness
- **4 - Severe:** Permanent disability
- **5 - Catastrophic:** Fatality

**Probability Scale:**
- **1 - Very Unlikely:** <1% chance per year
- **2 - Unlikely:** 1-10% chance per year
- **3 - Possible:** 10-50% chance per year
- **4 - Likely:** 50-90% chance per year
- **5 - Very Likely:** >90% chance per year

**Risk Matrix:**
| Hazard | Severity | Probability | Risk Score | Risk Level | Priority |
|--------|----------|-------------|------------|------------|----------|
| Chemical Exposure | 4 | 2 | 8 | Medium | 2 |
| Machine Guarding | 5 | 3 | 15 | High | 1 |
| Ergonomic Strain | 3 | 4 | 12 | High | 1 |

**CONTROL MEASURES HIERARCHY**

**Elimination (Most Effective):**
- **Hazard:** Remove {hazard_types} from {workplace_area} where possible
- **Control:** Eliminate hazard source through process redesign
- **Implementation:** Within {assessment_timeline} for critical hazards
- **Effectiveness:** 100% risk reduction when feasible

**Substitution:**
- **Hazard:** Replace high-risk {hazard_types} with safer alternatives
- **Alternative:** Substitute materials, processes, or equipment
- **Implementation:** Phased approach within {assessment_timeline}
- **Effectiveness:** 80-95% risk reduction typically achieved

**Engineering Controls:**
- **Hazard:** Control {hazard_types} through physical barriers
- **Control:** Guards, ventilation, isolation, automation
- **Implementation:** Priority installation per {risk_level} assessment
- **Effectiveness:** 70-90% risk reduction when properly designed

**Administrative Controls:**
- **Hazard:** Manage {hazard_types} exposure through procedures
- **Control:** Training, procedures, signage, job rotation
- **Implementation:** Immediate for {employee_count} workforce
- **Effectiveness:** 50-70% risk reduction with consistent application

**Personal Protective Equipment (Least Effective):**
- **Hazard:** Individual protection from {hazard_types}
- **PPE Required:** Appropriate for {workplace_area} conditions
- **Implementation:** Immediate provision per {compliance_standards}
- **Effectiveness:** 30-50% risk reduction when used correctly

**SPECIFIC CONTROL MEASURES**

**High-Risk Areas (Risk Score 15-25):**
1. **Critical {hazard_types} in {workplace_area}**
   - **Immediate Actions:** Implement emergency controls within 24 hours
   - **Short-term Controls:** Engineering solutions within {assessment_timeline}
   - **Long-term Solutions:** Permanent risk reduction measures
   - **Responsible Person:** Safety Manager and Area Supervisor
   - **Target Date:** Priority completion per {assessment_timeline}

**Medium-Risk Areas (Risk Score 8-14):**
1. **Moderate {hazard_types} exposure areas**
   - **Control Measures:** Administrative and engineering controls
   - **Implementation Plan:** Phased approach within {assessment_timeline}
   - **Monitoring:** Regular inspection and measurement
   - **Review Date:** Quarterly assessment and adjustment

**Low-Risk Areas (Risk Score 1-7):**
1. **Lower {risk_level} {hazard_types} areas**
   - **Control Measures:** Standard safety procedures and PPE
   - **Monitoring:** Routine inspection and employee feedback
   - **Review Frequency:** Annual assessment or as needed

**SAFETY PROCEDURES & PROTOCOLS**

**Standard Operating Procedures:**
- **Equipment Operation:** Safe work procedures for {workplace_area}
- **Chemical Handling:** Protocols specific to {hazard_types}
- **Emergency Procedures:** Response plans for {risk_level} scenarios
- **Maintenance Procedures:** Safety protocols for {employee_count} workers

**Training Requirements:**
- **General Safety Training:** Basic safety for all {employee_count} employees
- **Job-Specific Training:** {Hazard_types} awareness for {workplace_area}
- **Refresher Training:** Annual updates per {compliance_standards}
- **Competency Assessment:** Skills verification within {assessment_timeline}

**PERSONAL PROTECTIVE EQUIPMENT**

**PPE Requirements by Area:**
- **{Workplace_area} specific requirements:** Based on {hazard_types} exposure
- **High-risk zones:** Enhanced protection for {risk_level} areas
- **General areas:** Standard PPE per {compliance_standards}

**PPE Management:**
- **Selection Criteria:** Appropriate for {hazard_types} in {workplace_area}
- **Inspection Schedule:** Regular checks per {compliance_standards}
- **Replacement Program:** Timely replacement within {assessment_timeline}
- **Training Requirements:** PPE training for all {employee_count} workers

**EMERGENCY PREPAREDNESS**

**Emergency Procedures:**
- **Fire Emergency:** Evacuation and response for {workplace_area}
- **Chemical Spill:** Containment procedures for {hazard_types}
- **Medical Emergency:** First aid and emergency response
- **Evacuation Plan:** Safe egress for {employee_count} personnel

**Emergency Equipment:**
- **Fire Suppression:** Systems appropriate for {workplace_area}
- **Spill Response:** Kits specific to {hazard_types}
- **First Aid:** Medical supplies for {employee_count} workforce
- **Communication:** Emergency notification systems

**MONITORING & REVIEW**

**Performance Indicators:**
- **Incident Rate:** Target zero incidents for {risk_level} hazards
- **Near Miss Reports:** Encourage reporting from {employee_count} employees
- **Training Completion:** 100% completion within {assessment_timeline}
- **Audit Scores:** Meet {compliance_standards} requirements

**Review Schedule:**
- **Monthly Safety Meetings:** Regular reviews for {workplace_area}
- **Quarterly Assessments:** {Hazard_types} evaluation and updates
- **Annual Comprehensive Review:** Complete assessment per {assessment_timeline}
- **Post-Incident Reviews:** Immediate investigation and corrective action

**COMPLIANCE REQUIREMENTS**

**OSHA Standards:**
- **General Industry (29 CFR 1910):** Applicable standards for {workplace_area}
- **Construction (29 CFR 1926):** If applicable to {workplace_area} activities
- **Specific Standards:** {Compliance_standards} relevant to {hazard_types}

**Documentation Requirements:**
- **Risk Assessment Records:** Complete documentation per {compliance_standards}
- **Training Records:** Training completion for {employee_count} workers
- **Incident Reports:** Documentation of {hazard_types} incidents
- **Inspection Records:** Regular inspection logs for {workplace_area}

**ACTION PLAN**

**Immediate Actions (within {assessment_timeline}):**
1. **Address {risk_level} hazards in {workplace_area}**
   - **Responsible:** Safety Manager and Area Supervisor
   - **Due Date:** Priority completion within {assessment_timeline}
   - **Resources:** Safety team and {employee_count} workforce

**Short-term Actions (1-6 months):**
1. **Implement controls for {hazard_types}**
   - **Responsible:** Engineering and Safety Teams
   - **Due Date:** Phased implementation per {assessment_timeline}
   - **Resources:** Capital investment and training programs

**Long-term Actions (6+ months):**
1. **Continuous improvement for {workplace_area}**
   - **Responsible:** Management and Safety Committee
   - **Due Date:** Ongoing per {assessment_timeline}
   - **Resources:** Sustained investment and culture development

**RESULT:** Ensure your safety risk assessment demonstrates:

**Comprehensive Coverage:**
- Systematic identification of {hazard_types} in {workplace_area}
- Thorough evaluation of {risk_level} using standardized methodology
- Effective control measures following hierarchy of controls
- Clear action plans within {assessment_timeline}

**Regulatory Compliance:**
- Full compliance with {compliance_standards} requirements
- Proper documentation and record keeping
- Regular monitoring and review processes per {assessment_timeline}
- Continuous improvement and updates

**Worker Protection:**
- Effective {hazard_types} elimination and {risk_level} reduction
- Appropriate PPE selection for {workplace_area}
- Comprehensive training for {employee_count} employees
- Emergency preparedness aligned with {compliance_standards}

Create comprehensive preventive maintenance program for {equipment_type} using {maintenance_strategy}:

**SITUATION:** You need to develop a robust preventive maintenance program that maximizes equipment reliability, minimizes unplanned downtime, reduces maintenance costs, and ensures optimal equipment performance.

**TASK:** Design a systematic maintenance approach that prevents equipment failures, extends asset life, and optimizes maintenance resources while maintaining production efficiency.

**ACTION:** Structure your preventive maintenance program using proven reliability-centered maintenance principles:

**PROGRAM OVERVIEW**
- **Equipment Type:** {equipment_type}
- **Maintenance Strategy:** {maintenance_strategy}
- **Maintenance Frequency:** {maintenance_frequency}
- **Performance Targets:** {performance_targets}
- **Maintenance Budget:** {maintenance_budget}
- **Facility Size:** {facility_size}

**EQUIPMENT ANALYSIS**
- **Equipment Type:** Comprehensive analysis of {equipment_type} systems
- **Facility Size:** Maintenance scope across {facility_size} operations
- **Performance Targets:** Achievement of {performance_targets} objectives
- **Maintenance Strategy:** Implementation of {maintenance_strategy} approach

**MAINTENANCE STRATEGIES**

**Time-Based Maintenance (TBM):**
**Equipment:** Critical {equipment_type} requiring scheduled maintenance
**Maintenance Tasks:**
- **Daily Inspections:** Operator-based checks per {maintenance_frequency}
- **Weekly Maintenance:** Routine servicing and lubrication
- **Monthly Maintenance:** Detailed inspections and adjustments
- **Quarterly Maintenance:** Component replacement and calibration
- **Annual Overhauls:** Major maintenance aligned with {performance_targets}

**Condition-Based Maintenance (CBM):**
**Equipment:** {Equipment_type} with condition monitoring capabilities
**Monitoring Parameters:**
- **Vibration Analysis:** Continuous monitoring for bearing and alignment issues
- **Temperature Monitoring:** Thermal analysis for overheating detection
- **Oil Analysis:** Lubricant condition and contamination assessment
- **Electrical Monitoring:** Power quality and motor performance analysis

**Predictive Maintenance (PdM):**
**Equipment:** Advanced {equipment_type} with predictive capabilities
**Predictive Technologies:**
- **Vibration Analysis:** Trend analysis and failure prediction
- **Thermography:** Infrared imaging for electrical and mechanical issues
- **Ultrasonic Testing:** Detection of leaks, bearing wear, and electrical faults
- **Motor Current Analysis:** Electrical signature analysis for motor health

**MAINTENANCE SCHEDULES**

**Daily Maintenance (Operator-Based):**
**Time:** Start of shift for {equipment_type}
**Duration:** 15-30 minutes per {maintenance_frequency}
**Tasks:**
- **Visual Inspection:** Check {equipment_type} for obvious issues
- **Lubrication:** Apply lubricants per {maintenance_strategy}
- **Cleaning:** Remove debris and maintain cleanliness
- **Basic Adjustments:** Minor adjustments within operator capability

**Weekly Maintenance:**
**Time:** Scheduled downtime per {maintenance_frequency}
**Duration:** 2-4 hours depending on {facility_size}
**Tasks:**
- **Detailed Inspection:** Comprehensive {equipment_type} assessment
- **Filter Changes:** Replace filters per {maintenance_strategy}
- **Belt Tension Check:** Adjust belt tensions and alignments
- **Calibration Checks:** Verify accuracy and performance

**Monthly Maintenance:**
**Time:** Planned maintenance window per {maintenance_frequency}
**Duration:** 4-8 hours based on {equipment_type} complexity
**Tasks:**
- **Component Replacement:** Replace wear items per schedule
- **Alignment Checks:** Precision alignment verification
- **Performance Testing:** Validate {performance_targets} achievement
- **Preventive Repairs:** Address potential failure points

**Quarterly Maintenance:**
**Time:** Extended maintenance shutdown per {maintenance_frequency}
**Duration:** 1-3 days depending on {facility_size} scope
**Tasks:**
- **Major Inspections:** Comprehensive {equipment_type} evaluation
- **Overhaul Planning:** Plan major maintenance activities
- **Spare Parts Review:** Inventory assessment within {maintenance_budget}
- **Performance Analysis:** Review {performance_targets} achievement

**MAINTENANCE PROCEDURES**

**Standard Operating Procedures:**
1. **{Equipment_type} Preventive Maintenance**
   - **Scope:** Comprehensive maintenance per {maintenance_strategy}
   - **Safety Requirements:** Lockout/tagout and PPE protocols
   - **Tools Required:** Standard tools and specialized equipment
   - **Step-by-Step Instructions:** Detailed procedures for {equipment_type}
   - **Quality Checks:** Verification of {performance_targets}

2. **{Equipment_type} Condition Monitoring**
   - **Scope:** Monitoring activities per {maintenance_frequency}
   - **Safety Requirements:** Safe access and measurement protocols
   - **Tools Required:** Monitoring equipment and data collection tools
   - **Step-by-Step Instructions:** Systematic condition assessment
   - **Quality Checks:** Data validation and trend analysis

**Work Order Management:**
- **Work Order Creation:** Systematic process for {equipment_type} maintenance
- **Priority Classification:** Based on criticality and {performance_targets}
- **Resource Allocation:** Optimize within {maintenance_budget} constraints
- **Completion Verification:** Quality assurance and documentation

**SPARE PARTS MANAGEMENT**

**Critical Spare Parts:**
- **{Equipment_type} critical components:** Maintain adequate stock levels
- **High-wear items:** Inventory based on {maintenance_frequency}
- **Emergency spares:** Strategic inventory for {facility_size} operations

**Inventory Management:**
- **Minimum Stock Levels:** Based on {equipment_type} criticality
- **Reorder Points:** Aligned with {maintenance_frequency} requirements
- **Supplier Management:** Reliable sources within {maintenance_budget}
- **Cost Optimization:** Balance inventory costs with availability needs

**PERFORMANCE METRICS**

**Equipment Performance:**
- **Overall Equipment Effectiveness (OEE):** Target per {performance_targets}
- **Mean Time Between Failures (MTBF):** Improve reliability for {equipment_type}
- **Mean Time To Repair (MTTR):** Minimize downtime through {maintenance_strategy}
- **Equipment Availability:** Maximize uptime across {facility_size}

**Maintenance Performance:**
- **Planned vs. Unplanned Maintenance Ratio:** Optimize per {maintenance_frequency}
- **Maintenance Cost per Unit:** Control within {maintenance_budget}
- **Schedule Compliance:** Achieve {performance_targets} adherence
- **First-Time Fix Rate:** Improve efficiency for {equipment_type}

**RESOURCE PLANNING**

**Workforce Requirements:**
- **Maintenance Technicians:** Adequate staffing for {facility_size}
- **Specialists:** {Equipment_type} experts and technical support
- **Contractors:** External support within {maintenance_budget}
- **Training Needs:** Skills development per {maintenance_strategy}

**Tool and Equipment Needs:**
- **Hand Tools:** Standard maintenance tools for {equipment_type}
- **Diagnostic Equipment:** Condition monitoring tools per {maintenance_strategy}
- **Lifting Equipment:** Safe handling equipment for {facility_size}
- **Safety Equipment:** PPE and safety systems for maintenance work

**TRAINING & COMPETENCY**

**Training Program:**
- **Basic Maintenance Skills:** Fundamental skills for {equipment_type}
- **Equipment-Specific Training:** Specialized training per {maintenance_strategy}
- **Safety Training:** Safe maintenance practices across {facility_size}
- **Predictive Maintenance Training:** Advanced techniques for {equipment_type}

**Competency Assessment:**
- **Skill Levels:** Competency standards for {equipment_type} maintenance
- **Certification Requirements:** Professional certifications per {maintenance_strategy}
- **Ongoing Development:** Continuous learning within {maintenance_budget}

**CONTINUOUS IMPROVEMENT**

**Performance Review:**
- **Monthly Reviews:** {Equipment_type} performance against {performance_targets}
- **Quarterly Analysis:** {Maintenance_strategy} effectiveness evaluation
- **Annual Assessment:** Comprehensive program review per {maintenance_frequency}
- **Benchmarking:** Industry comparison for {facility_size} operations

**Improvement Initiatives:**
- **Root Cause Analysis:** Systematic failure investigation for {equipment_type}
- **Failure Analysis:** Technical analysis and prevention strategies
- **Process Optimization:** {Maintenance_strategy} refinement and enhancement
- **Technology Upgrades:** Advanced solutions within {maintenance_budget}

**IMPLEMENTATION PLAN**

**Phase 1: Foundation (Months 1-3)**
- **Equipment Assessment:** Comprehensive {equipment_type} evaluation
- **Procedure Development:** {Maintenance_strategy} documentation
- **Team Training:** Initial training for {facility_size} workforce
- **System Setup:** Infrastructure and tools within {maintenance_budget}

**Phase 2: Deployment (Months 4-6)**
- **Pilot Implementation:** {Equipment_type} pilot program
- **Schedule Optimization:** {Maintenance_frequency} refinement
- **Performance Monitoring:** {Performance_targets} tracking systems
- **Feedback Integration:** Continuous improvement process

**Phase 3: Optimization (Months 7-12)**
- **Full Implementation:** Complete {facility_size} deployment
- **Performance Analysis:** {Performance_targets} achievement assessment
- **Continuous Improvement:** {Maintenance_strategy} optimization
- **Program Maturation:** Sustainable maintenance excellence

**RESULT:** Ensure your preventive maintenance program demonstrates:

**Reliability Excellence:**
- Systematic approach to {equipment_type} maintenance and reliability
- Proactive failure prevention using {maintenance_strategy}
- Optimized {maintenance_frequency} schedules and resource utilization
- Continuous improvement achieving {performance_targets}

**Operational Efficiency:**
- Maximized {equipment_type} uptime and availability
- Reduced unplanned downtime through {maintenance_strategy}
- Optimized maintenance costs within {maintenance_budget}
- Improved overall equipment effectiveness across {facility_size}

**Strategic Value:**
- Extended {equipment_type} life and asset value preservation
- Enhanced production capacity meeting {performance_targets}
- Reduced total cost of ownership within {maintenance_budget}
- Competitive advantage through {maintenance_strategy} excellence

**Program Integration:**
- {Equipment_type} maintenance optimized per {maintenance_strategy}
- {Maintenance_frequency} schedules supporting {performance_targets}
- {Maintenance_budget} allocation maximizing value across {facility_size}
- Sustainable maintenance culture delivering operational excellence