Lean Tools for process improvement


Lean Tools

Excel templates for lean process improvement

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Lean Process Improvement Tools

Lean Tools for 5S Problem Identification

Newcomers often mistakenly believe that 5S is just about being clean and organized.

People who have been fortunate enough to be part of a successful lean team
know that the primary reasons for doing 5S are:

  1. to reveal problems

    because problems can't be solved until they are revealed

  2. to establish a culture
    where people are encouraged to reveal problems

    because any process that appears to have no problems

    is certain to be concealing huge problems
    that will never be fixed until management makes it safe for people to shine bright spotlights in previously dark corners

Your Systems2win Lean Tools include an entire suite of 5S templates started right, and keep it on track for many years of consistent process improvement habits.

Lean Tools for Standard Work

The 4th S... "Standardize"... is by far the most difficult of the 5 S's... and the most important.


What's the point of trying to improve anything
if your people just nod their heads and pretend to go along with the agreed-upon changes,

and then just go right back to doing things the same way they've always done them?

Your Systems2win Lean Tools include an entire suite of Standard Work templates to analyze, improve, and control any type of process.

(even yours)

Lean Tools for Training

As things change, your people need to be trained to do things the new ways.


By definition, continuous improvement is continuous.

We're not living in the 1800's any more. In this 21st century, things change often and change fast.

Without excellent systems for rapid, reliable training and re-training,
there will be mistakes that affect quality, mistakes that affect safety, mistakes that affect costs...

Your Systems2win templates include an entire suite of Lean Training templates to document Work Instructions, comply with ISO 9000, FDA, and other controlled compliance environments, and to use TWI Job Instruction methods and Standard Work Audits to ensure that your people actually learn and practice new skills in the ways that (you thought) you taught them.

Lean Tools for Process Observation Analysis

Go to the gemba and see.


The gemba is where the work actually happens.

You can't do lean process improvement by sitting in a conference room shuffling through inaccurate process routings and time standards.

Your Systems2win Lean Tools include an entire suite of templates to observe and analyze your processes in diverse field-proven ways.

Lean Tools for Heijunka Load Balancing

Lean doesn't require flow, but the closer you can get, the better results you will get.

Flow requires load balancing.

Load balancing is achieved in many different ways for many different work environments.


A medical office will achieve flow using lean tools and methods that are different from the way that an assembly line will achieve flow.

An engineering department will achieve flow using lean tools and methods that are different from the way that a machine shop will achieve flow.

Your Systems2win Lean Tools include an entire suite of Heijunka Load Balancing templates to serve as visual controls to monitor flow through any type of work center.

Flowcharts and Process Engineering

Some processes simply don't fit well with traditional lean tools and methods.

Flowchart template Swim Lane Functional Flow Chart
Flowcharts and Process Engineering templates


For some reason, God invented ERP systems, lengthy projects, and complex processes that easily get tangled up and hard to analyze.

Your Systems2win Lean Tools include many types of flowcharts and Process Engineering templates to help you untangle complex processes.



Lean Tools in a typical lean journey

How to choose the right tools

Tool Matrix

Use your Tool Selection Matrix (1ToolSelection.xlsx)
to select the right Process Improvement Tools for what you need next.

A typical lean journey starts with some combination of
value stream mapping, kaizen, and/or 5S workplace organization.

It usually isn't long before you reach that all-important fourth S — "Standardize" —

yellow brick road

Road map for a
typical lean journey

and you learn first-hand how important it is to lock in your gains
with Standard Work, and Visual Work Instructions — 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.

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an enterprise license
to empower every member of your team


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Download free trial lean tools

which includes sheets for Layout Diagram and
TWI Job Breakdown









What's so wrong with backsliding into old habits?











Did your consultant leave you with teachable, repeatable systems?

There are valid reasons why a consultant might want newcomers to learn unfamiliar lean methods using pencil and paper, and some lean methods really can be done forever using only pencil and paper, but many of those reasons dry up once your managers are left to mentor a large number of people using a large number of lean methods over a long period of time.

In the end, it becomes your leadership responsibility to choose the lean tools and lean training systems to affordably support and perpetuate your lean management systems and your lean culture.

Contact us to schedule an appointment to learn how some Systems2win templates might fill some holes in your lean tool kit.




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