We cut a packaging line changeover from 22 to 14 minutes last quarter, but near-misses ticked up; I’m looking for a repeatable method to protect safety while holding schedule gains. Has anyone got a solid template for an 8-minute daily floor huddle that ties takt targets, LOTO confirmations, and schedule risk into a single view (MES add-on or paper)?
We made the huddle start with a 60‑second LOTO roll‑call that gates everything: each area lead scans their badge on an Ignition screen and says “LOTO verified, guards in place,” the board flips green only when all zones confirm, and we don’t post takt or release changeovers until then — near‑misses dropped 38% without losing cycle gains. If you’re not on MES, the paper version is a magnet strip checklist with initials and a red/green slider — would that fit your 8‑minute flow?
Quick win that worked for me: make the 8‑minute huddle a single A3 board with three boxes — Takt vs Actual, LOTO status, and Today’s Risks — and use red kamishibai cards to physically verify LOTO on any line with a scheduled changeover; no card, no start. We tracked changeovers like your 22→14 and only banked the faster time when the risk box had a named countermeasure/owner; otherwise we kept the old time and a visible 10‑min buffer (, but near‑misses dropped). If you need a template, this daily management example is easy to tweak: https://www.lean.org/explore-lean/daily-management/ — would A3+kamishibai work for you, or are you leaning M.