Flow and takt
Pace, balance and level the work.
CalculatorHeijunka GeneratorLevel a product mix across slots and see the board.CalculatorTakt Time CalculatorTakt, cycle time check and operators needed.CalculatorKanban CalculatorSize cards and zones from demand and lead time.ChartYamazumi ChartStacked work content per station against takt.ChartStandard Work Combination ChartOperator and machine time per step.ToolStopwatch Time StudyLap timer for observed cycle times.
Quality and problem solving
Find the cause and prove the process is stable.
TemplateA3 Problem SolvingOne-page A3 report from problem to follow-up.TemplateRoot Cause Analysis (5 Whys and Fishbone)5 Whys and fishbone in one place.CalculatorFMEA WorksheetRank failure modes by RPN.ChartPareto ChartSort causes and find the vital few.ChartControl Chart (I-MR)Individuals chart with limits and signals.CalculatorHistogram and CpkProcess capability against spec limits.TemplateRisk Matrix5 by 5 likelihood and impact scoring.
Improvement and TPM
Choose, run and measure improvements.
CalculatorOEE CalculatorAvailability, performance and quality.TemplateSMED Changeover AnalysisSplit changeover into internal and external work.TemplateKaizen ReportBefore and after result with payback.ChartImpact and Effort MatrixPrioritise ideas on a 2 by 2 grid.CalculatorImprovement ROI CalculatorPayback, ROI and NPV.TemplateWaste Log (8 Wastes)Record the eight wastes and see the mix.Checklist5S AuditScore each S by area and track the trend.TemplateRed Tag LogDecisions on items cleared from an area.
Standard work and floor routines
Make the standard visible and check it.
TemplateStandard Work InstructionStep-by-step instruction sheet.TemplateOne Point LessonOne page that teaches one skill.ChecklistGemba Walk ChecklistQuestions for a structured walk.ChecklistDaily Equipment CheckOperator start-of-shift machine care.ChecklistSafety Walk ChecklistWorkplace safety inspection.TemplateSIPOC DiagramScope a process on one page.ToolProcess FlowchartType steps, get a flowchart.
Supply chain and procurement
Stock, buy and deliver at the right cost.
CalculatorABC AnalysisClassify items by usage value.CalculatorEOQ and Reorder PointOrder size, safety stock and reorder point.CalculatorLanded Cost CalculatorTrue cost per unit of imported goods.TemplateSupplier ScorecardWeighted supplier ranking.TemplateQuote Comparison (RFQ)Compare supplier quotes side by side.CalculatorOTIF TrackerOn-time in-full by period.CalculatorInventory TurnsTurns and days on hand.PlannerCycle Count PlannerCount frequency by ABC class.
Image library
Original lean diagrams with labels.
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