Lean Process Improvement Tools
Excel templates for lean process improvement
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Excel templates for lean process improvement
Spaghetti Map Layout Diagram
To create spaghetti diagrams, floor plans, and easy-to-understand work instructions.
The Layout Diagram template can be used for simple floor planning purposes, but it really shines as a spaghetti mapping tool for lean process improvement.
Download free trial Layout Diagram (within Standard Work template)
Lean Manufacturing tool
Standard Work Combination Sheet
6 tools in 1:
The Standard Work Sheet is perhaps the most important of all Lean Kaizen tools.
Major upgrade — see what's new for lean tools
Standard Work Table & Chart —
The ideal process improvement template
Auto-draws from the Standard Work Combination Sheet
Download free trial Standard Work Combination Sheet
Standard Work Table
Work Load Balancing Chart
To determine the optimal staff size, and balance the work load. This is a fantastic process improvement tool for analyzing "what if" scenarios for different Takt times caused by different customer demand loads.
Auto-draws on the Standard Work Analysis sheet
Machine Load Balancing for Lean Manufacturing
Lean template to ensure that equipment is capable of meeting Takt Time, and to answer what-if questions regarding equipment loading decisions.
Learn more about the Machine Balancing template
Time Observation Worksheets
Time Observation Sheet template to objectively study and time a process for Lean process improvement
Choose between two different Process Observation Worksheets:
1) For highly repetitive short processes
2) For processes more vulnerable to process variances
And both process improvement templates come with online training and an interview questionnaire to greatly improve the creative thinking of both the observer and the process worker.
Tip: The Standard Work Sheet has the option to use either stopwatch or video time observation
The right questions to ask when interviewing workers at gemba,
Lean Management tool to ensure that work is actually being done in compliance with Standard Work Instructions.
Many novice Lean teams do everything right — and then fumble the ball at the last possible moment — by failing to supervise their supervisors to ensure that they are supervising — to make sure that people really are doing things the way that everyone agreed was the best way to do them.
To establish lean process design objectives and compare to projected and actual results — managing the ∆Delta Change gap analysis.
Tip: The Value Stream Map can also be used for a similar purpose, but at a higher perspective
A3 Illustrator for Stick Figure Drawing
5S Check List
Purpose: To measure and improve 5s workplace organization, instill 5s philosophy, and evaluate success of your 5s program implementation
Download free trial 5S Checklist
|Process Engineering Tools |
Business Process Improvement using Process Reengineering methods
Flow Chart Template
This is a pure and simple easy to use flowchart template
It runs on the same Microsoft Excel that your people already own and (hopefully) know how to use
One popular use is to create a Mix Logic Flowchart for lean level scheduling.
flow chart template
Cross Functional Flowchart
Most business process engineering starts with a functional flow chart template — which has a swim lane for each person, department, or functional team that is involved with the process — showing an intuitive graphic depiction of who is doing what, when, where, and for how long.
Don't be surprised if this swim lane flow chart turns out to be the most used template in your lean toolkit.
Download free trial swim lane cross functional flowchart template
Cross Functional Flowchart
Business Process Reengineering Matrix
If you've ever had a flow chart with too much information, you will appreciate this process engineering tool to untangle even the most complex workflow diagram.
Each row correlates to (and can be hyperlinked from) a box
Fill-in-the-blanks columns cover every process engineering concept taught within Ray Manganelli's Reengineering Handbook.
Includes a CRUDS matrix to clarify exactly who is doing what where with every piece of paper and every element of data for every step of your process.
Value Add Analysis pie chart and Activity Based Costing analysis make it easy to identify and eliminate waste.
Process improvement tool
Jobs Design Matrix
Once you have finished business process redesign, the very next question is: "How will this affect people's jobs?"
"How many people will we need?""How will we handle peak volume spikes?""What new skills will be required for the new jobs?""How do those compare with our existing jobs?""What might be logical career paths?"
The Jobs Design Matrix helps your team to organize and document
|When doing process engineering, the Strategic Planning worksheets can also be helpful|
|Lean Training templates|
Training Matrix / Skills Matrix
Can Roger take a vacation? This Excel template is often used as a Cross Training Matrix to define and measure the skills and training that your people have vs. the skills and training they need.
To provide thorough training — using a combination of pictures and written instructions to minimize lost productivity and quality when training new-hires, temporaries, and vacation replacements.
While the Standard Work Combination Sheet is the right tool for analysis and process improvement — this Visual Work Instructions template is the right tool for (far more detailed) training for new-hires, temporaries, and vacation replacements.
Download free trial Job Instructions
It automatically renumbers your steps
Standard Operating Procedure
Use this popular template to document how to perform any operation procedure.
It comes with online help for how to use Word's numbered outline features to easily number (and renumber) process steps.
Supports Link Icons within Word documents
2 Learn Excel
Self-paced learning validation tool...
1) To learn some of the most powerful features of Microsoft Excel
Download free trial Self Paced Excel Learning Tool
2 Learn Excel — learn more
|Lean tools for TWI Training Within Industry|
Job Breakdown Sheet
Instructor Notes used by the supervisor to prepare to effectively train using the TWI Job Instructions training method.
Job Breakdown Instructor Notes
TWI Job Instructions Pocket Card
Pocket Card to quickly remind supervisors how to follow the TWI Job Instructions training method.
Easily personalized, and then
TWI Job Methods Pocket Card
Best practices reminder for how to practice lean process improvement
Easily personalized, but gives you a great start;succinctly summarizing modern lean methods that go way beyond original TWI teachings.
TWI Job Relations Pocket Card
Common sense four-step process for how supervisors should resolve conflicts between people
Easily personalized, starting with a template similar to the original TWI Job Relations card
Pocket Card for
For second line supervisors
Succinctly summarizes modern lean leadership teachings that you will find far more useful than the original TWI teachings for second line supervisors
|Heijunka Load Balancing Tools|
To level the flow of work
Learn more about Heijunka load balancing tools
Monthly Pitch Log
To provide at-a-glance visual analysis of trends for hour-by-hour attainment of the target production rate (known as "pitch")
Pull Queue Hourly Status
To view trends over time — of the log-jam status of work requests leading to a work center that responds to lean pull signals (such as a FIFO Lane)
Compare estimated to actual set up times and run times per job —
Process Improvement tools
in a typical lean journey
Use the Tool Matrix to select the right Process Improvement Tools
for what you're needing to accomplish.
It usually isn't long before you reach that all-important fourth S — "Standardize" —
and you learn first-hand how important it is to lock in your gains
with Standard Work, Visual Work Instructions, Standard Operating Procedures —
so that people don't simply backslide into old habits, and erode so many of your hard-won gains.
Most lean journeys start with customer-facing operations —
and then slowly make their way to white-collar lean office supporting functions.
Your Systems2win lean templates empower your people with the full suite of Process Improvement tools
to not only get you started on your Lean journey — but to grow with your people as they mature through the years; continuously improving your tools for continuous improvement.
Lean Manufacturing software that's exceptionally easy to learn
Your people already know how to use each powerful new Continuous Improvement tool —
The surprise prize that comes with these lean templates
The depth and clarity of online training is the biggest surprise for most new customers.
They buy these jit tools because they want time-saving templates,
and then are surprised that so much online lean training is instantly available and free.
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