Lean Tools

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)

Standard Work Combination Sheet

6 tools in 1:

1. layout diagram spaghetti map
2. concise standard work instructions
3. value add analysis & pie chart
4. work load balancing & bar chart
5. changeover setup reduction
6. standard work chart

The Standard Work Sheet is perhaps the most important of all Lean Kaizen tools.
If the people doing the actual work aren't doing it the way that your design team envisioned - then your entire effort was wasted.

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Standard Work Table & Chart -
Auto-draws!

The ideal process improvement template
to visually depict time for a repetitive process -
greatly facilitating your ability to design the process and eliminate waste

Auto-draws from the Standard Work Combination Sheet

Download free trial Standard Work Combination Sheet

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

A3 Gemba Interview

The right questions to ask when interviewing workers at gemba,
to systematically encourage both the observer and the process worker to come up with creative ideas for how to realize Lean Ideals by applying the 4 Rules In Use

Standard Work Audit

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 it.

Results Metrics Gap Analysis

To establish lean process design objectives and compare to projected and actual results - managing the ∆ Delta Change gap analysis.
Easily link real-time data from source worksheets from various business templates.

Tip: The Value Stream Map can also be used for a similar purpose, but at a higher perspective

A3 Illustrator for Stick Figure Drawing

A very easy to use tool to illustrate A3 Reports with intuitive stick figure drawings, and any other useful illustrations using Excel as a drawing tool.

Especially useful for Lean Office and Lean Healthcare

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

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.

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

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 on a flow chart.

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
for process engineering
of complex processes

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?" "What training is needed?" "How might we organize teams?" "How might we divide management responsibilities?"

The Jobs Design Matrix helps your team to organize and document its thoughts regarding these process engineering issues and more.

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.

View Training Matrix video

Cross Training Matrix

Job Instructions

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

View training videos

Job Instructions

It automatically renumbers your steps
and re-shuffles your images whenever you regenerate your printed (or PDF) report

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

Procedure template
More info

2 Learn Excel

Self-paced learning validation tool...

1) To learn some of the most powerful features of Microsoft Excel
2) To learn Systems2win's innovations that make Excel even more useful
3) To allow a Supervisor to validate that the Learner has learned - with one quick glance

 Download free trial Self Paced Excel Learning Tool

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
for using the TWI JI training method

TWI Job Instructions Pocket Card

Pocket Card to quickly remind supervisors how to follow the TWI Job Instructions training method.

Easily personalized, and then
perfectly sized for credit-card-size lamination.

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
second line supervisors

For second line supervisors
and Change Agents

Succinctly summarizes modern lean leadership teachings that you will find far more useful than the original TWI teachings for second line supervisors

Pitch Chart

To level the flow of work
and to measure expected vs. actual production per pitch cycle

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)

Job Log

Compare estimated to actual set up times and run times per job -
with explanations of reasons for each miss - which are then used to continuously improve the process