01 Trigger and authority What to do: Define who declares backup method.
Failure class Describe what went wrong, where it was noticed, and the practical effect. Example: Wrong product scanned; tote moved to EXC-01 Detection signal Explain how a worker or system notices the problem. Example: Zero stock found after location search Fallback threshold State the exact condition that starts the backup method. Example: Network unavailable for more than 5 minutes Decision owner Name the person responsible for this decision, task, or approval. Example: A. Rivera — Operations Manager Communication channel Name how the fallback decision is announced to every affected person. Example: Radio channel 2, supervisor text group, and whiteboard at staging
02 Manual operating mode What to do: Preserve identity and transaction order.
Work release method Explain how new work is numbered, prioritized, and handed out during fallback. Example: Supervisor issues sequential paper lists from the cutoff queue Location / item guidance Explain how workers identify the correct location and item during fallback. Example: Printed list shows location code, product code, description, and quantity Confirmation record Name the photo, report, scan, system record, or observation that proves the answer. Example: Event log 14:32 and photo IMG-10482 Exception record State where workers record problems during fallback and which details are required. Example: Numbered paper problem log with task, tote, code, time, and owner WIP limit Maximum work allowed to be started but unfinished. Example: 20 open totes Safety control Name the rule that prevents unsafe work while normal guidance is unavailable. Example: No picker enters the forklift refill lane without a spotter
03 Data preservation What to do: Make return to normal possible.
Last confirmed event Record the final task and time known to be safely completed before the failure. Example: Task 8472 completion accepted at 14:32:18 Offline record Name the photo, report, scan, system record, or observation that proves the answer. Example: Event log 14:32 and photo IMG-10482 Duplicate-prevention key Enter the unique ID that stops the same work from posting twice. Example: task_id 8472 Inventory hold State which items or locations must remain blocked until records are reconciled. Example: Hold locations A-01 through A-12 from allocation Order status State the safe software status used to keep fallback work from shipping or releasing twice. Example: MANUAL_HOLD until reconciliation is complete Reconciliation owner Name the person responsible for this decision, task, or approval. Example: A. Rivera — Operations Manager
04 Recovery What to do: Test the return path.
System validation List the checks that prove software, devices, and connections are ready to resume normal work. Example: Heartbeat current, test task completes once, and queues are visible Backlog sequence State the safe order for processing work that accumulated during the outage. Example: Ship-cutoff orders first, then oldest released work; keep held orders separate Reconciliation steps List the ordered checks used to match paper or offline work with the software record. Example: Match task IDs, post confirmed quantities, investigate differences, then release holds Resume authority Name the person responsible for this decision, task, or approval. Example: A. Rivera — Operations Manager Post-event review State when the review occurs, who joins, and what evidence will be examined. Example: Next business day with operations and IT; review logs, paper records, and held inventory
Keep related photos, drawings, reports, and system records with the saved PDF. This worksheet does not replace site-specific safety, quality, regulatory, or engineering review.
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