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The 3P Process Overview Form provides an at-a-glance view of the final process steps that will be implemented. It is a communication tool, as well as a review tool. By going through the process of filling out this form, the team will make sure they have considered each process step Read more…
The 5 Whys form is a simple tool that helps improvement teams find the root cause of a problem. This simple form documents the problem solver’s progress. Velaction’s version of the 5 Whys template adds in a unique feature: the confirmation step. One of the drawbacks of the 5 Whys Read more…
The 7 Ways Comparison form is a tool used to show an at-a-glance view of 7 process options created as the result of a brainstorming session. It is commonly used in 3P events, but is a useful tool in any situation in which a team needs to choose between several Read more…
The 7 Ways Idea Generation Form is a brainstorming tool that is used to encourage people to stretch their creativity. It is frequently used in 3P events, but is also useful in any problem-solving activity that would require an innovative solution. Get Our 7 Ways Idea Generation Form for Free Read more…
This A3 template can be used to create an A3 report, the communication medium for A3 problem solving. The A3 report takes its name from the “A3” size of paper that the report is generally written or printed on. (A3 paper is an international designation similar to the ledger size Read more…
The Countermeasure Sheet is a form used to track the actions necessary to get a KPI metric or other goal back on track. The basic steps to using the Countermeasure Sheet are: Fill out the header information. Create a problem statement. Do your homework and provide the background information. Do Read more…
The Daily Management Worksheet is a tool to help you update your production board. It has tabs for planning your demand and staffing. This information is automatically added to the production board worksheet to help you manage your day. The production board is the cornerstone of daily management. It is Read more…
The Decision Matrix Template is used to simplify the decision-making process and prevent emotional, gut decisions. In short, a decision matrix template helps users grade a set of options against a set of criteria. This template, like most decision matrix templates, includes a weighting system. It puts additional value on Read more…
The FMEA Worksheet (Failure Mode and Effects Analysis) supports the process of managing the risk associated with product or process failures. Traditionally an engineering tool, the FMEA Worksheet is also useful when assessing the risk of a Lean project. Watch Our FMEA Video The basic steps to using the FMEA Read more…
Interruptions plague workers, especially in the office. This simple log lets employees gain a better understanding of how much time they lose due to interruptions. It also helps them understand, and resolve, the root cause of the interruptions. Get Our Interruption Log for FREE
The Kaizen Audit Form is one of the sustaining tools used to lock kaizen gains in place. It is very easy to backslide after a project when there is no process in place to keep people from reverting to old methods of work. Get Our Kaizen Audit Form for FREE Read more…
A kaizen charter is a form that lays out the scope and goals of a rapid improvement project. Get Our Kaizen Charter Form for FREE The kaizen charter is a living document that evolves throughout the planning process. It establishes the team, and scopes the project, setting the goals and Read more…
The kaizen checklist is a tool used to avoid mistakes when conducting a kaizen event (a.k.a. kaizen blitz, rapid improvement workshop, etc.) A good kaizen checklist covers the planning, the actual event, and the follow-up work. It assigns specific people to tasks and gives deadlines for each action. Get Our Read more…
The Kaizen Newspaper is a tool for both managing workload during a kaizen event, and for keeping track of the follow-up activities. Get Our Kaizen Newspaper Form for FREE During the event, I recommend posting a version of this form up on a flipchart (in marker), or at least tape Read more…
A kanban card is small card containing information about a specific part used in production. It is a signal that tells someone upstream to move, purchase, or build more of a component for production. These cards must contain the number of units (items, pounds, kits, etc.) that need action. They Read more…
The KPI bowler gets its name from its resemblance to a bowling score sheet. Learn About the KPI Bowler in our Managing With Metrics Video The form is used to track progress towards meeting key performance indicators. When the results are below the target, the block should be highlighted in Read more…
The Noise to Constant Sheet is a tool for organizing and prioritizing effort in an improvement project. The first step to creating a consistent, correct output of a process is to reduce variation. This form lists the noise in a process (the randomness or uncontrolled aspects) and asks teams to Read more…
Managing workload in an office setting can be a challenge. Use the Office Process Capacity Form to determine whether a process is sufficiently staffed to meet demand. This form takes the FTE (full time equivalent) load into account, as many office workers have multiple roles. Get Our Office Process Capacity Read more…
The Office Process Questionnaire is a tool to help gather information from office workers during the process walk of a kaizen event. Get Our Office Process Questionnaire for FREE It has a series of standard questions, as well as space to record questions specific to the process under review. Adding Read more…
The Process Recording Sheet is primarily used to document steps in an office environment during a process walk. Because of the non-linear flow in an office, longer cycle times, computer processes that are hard to monitor, and the frequency with which office workers change tasks, a Time Observation Sheet is Read more…
The Office Process Summary Sheet provides an at-a-glance view of the gains an improvement team has made in a kaizen event. Get Our Office Process Summary Sheet for FREE The Office Process Summary Sheet has some of the most common measures of improvement already filled in, and also provides a Read more…
A Pareto chart is a valuable prioritization and communication tool. It is simply an ordered bar chart showing the most common item on the left and the least common on the right. This tool capitalizes on the 80/20 rule. In effect, this rule says that 80% of whatever it is Read more…
Policy deployment is a process of turning the strategic goals of an organization into actionable tasks at the frontline of an organization. This systematic approach to leadership clearly defines the path to success. One of the tools used in effective policy deployment is the Policy Deployment Action Plan. Get Our Read more…
The Policy Deployment Bowler is used to track progress on the targets shown on a Policy Deployment Matrix. In policy deployment, 3 to 5 year strategies are turned into annual objectives. To meet those objectives, leaders establish improvement priorities, which generally require new processes. If the progression through policy deployment Read more…
Policy deployment is the process of turning a strategic vision into an actionable task that frontline leaders and employees can commit to. Even with a great strategy and a highly effective team that is capable of making substantial improvements, a company can fall short of its goals. Why? The two Read more…
The Problem Barrier Assessment Sheet is used to isolate the obstacles to effective problem solving in your company. When you recognize a problem, note it on the sheet, and then investigate why the problem has persisted. Most problems did not just jump up recently. They have been around for a Read more…
The red tag system is simply a communication tool used to identify items that a person has flagged for removal from a work area. While the tagging is most frequently done during kaizen events, it can be done at any time. In a nutshell, when a person finds an item Read more…
The SIPOC Analysis Sheet is a tool to help understand the flow of value from supplier to the customer. SIPOC is the acronym for Supplier-Inputs-Process-Outputs-Customer. Click Image to Get Our SIPOC Analysis Sheet(Get This Form for Free) In practical use, a simple form such as this has limitations. Suppliers often Read more…
A Standard Work Combination Sheet (SWCS) is also known as a Standard Work Combination Chart, or a Standardized Work Combination Table. Regardless of what you call it, it is one of the most critical documents to your Lean success. Standard Work Combination Sheets goes hand-in-hand with Standard Work Sheets. In Read more…
The Standard Work Sheet is a staple form for Lean Manufacturing. It provides a graphical view of the workstation, the path of the operator, and the amount of standard work-in-process required to keep the process flowing smoothly. This form goes hand-in-hand with the Standard Work Combination Sheet. Directions for the Read more…
A takt time calculator is simply a tool, usually a spreadsheet, with the takt time calculations already programmed in. It is most useful for people who don’t routinely calculate takt time. The takt time calculator should take people through all the steps of determining takt time. Get Our Takt Time Read more…
The Time Observation Sheet is one of the four primary forms for developing Standard Work. The others are: The Standard Work Sheet The Standard Work Combination Sheet Work Instructions The Time Observation Sheet is used to, not surprisingly, observe the cycle times of the steps of Standard Work. Unfortunately, many Read more…
Value Stream Mapping is an extremely powerful tool that gives an organization a unified understanding on how processes link together to form a ‘value stream’ that turns raw materials, components, and information into something that a customer wants.
While most Lean practitioners will instruct you to create the map with pencil and paper on the shop floor, there is a benefit to transferring that information onto a digital format that can be easily annotated, updated, and shared.
The waste recording form is a simple tool for documenting waste during a process walk. The observer focuses on identifying the wasteful activities a person is performing and records them on the form. The form will usually contain a place to categorize the waste. Waste reduction is a large part Read more…