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:
- to reveal problems
because problems can't be solved until they are revealed
- to establish a culture
where people are encouraged to reveal 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.
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.
Some processes simply don't fit well with traditional lean tools and methods.
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
Use your Tool Selection Matrix (1ToolSelection.xlsx)
to select the right Process Improvement Tools for what you need next.
It usually isn't long before you reach that all-important fourth S — "Standardize" —
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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