Free Lean Tools

Visualize manual, auto, walking, and waiting time against takt time. Draw timelines, add work elements, and export print-ready documents.

Map your work area layout, trace the operator walking path, mark quality checks and safety points, and record takt/cycle metrics. Export print-ready charts.

Break any job into important steps, key points, and reasons — the TWI Job Instruction method — with a photo per step. Manufacturing, healthcare, café, warehouse, and home examples, plus a free print-ready Excel template.

Calculate machine capacity per shift, identify bottleneck processes, and document tool change impacts. The foundation for standardized work analysis.

Record 10 observation cycles per work element, identify the lowest repeatable time, flag outliers, and export print-ready study forms.

Trace the path a worker, patient, material, or document travels through a space. Measure total distance, count the crossings that reveal motion waste, and prove a layout redesign. Manufacturing, restaurant, healthcare, construction, and office examples, a watch-and-trace practice mode, and a free print-and-walk Excel template.

Map material and information flow across your value stream. Identify the gap between lead time and processing time. Includes manufacturing, healthcare, and insurance examples.

Ishikawa diagram for root cause analysis. Map causes across Man, Machine, Material, Method, Measurement, and Environment, then drill down with 5-Whys to reach root causes.

Sort problem categories by frequency and overlay a cumulative line to find the "vital few" causes behind most of the effect. Set an 80/20 focus threshold, edit your own counts, and export print-ready charts.

Convert any defect rate into a Six Sigma level, DPMO, and yield. Enter units, opportunities per unit, and defects — with the 1.5σ shift, a color sigma gauge, a full conversion table, and worked examples across manufacturing, healthcare, software, and financial services.

Calculate Cp and Cpk from spec limits and process statistics — or paste raw data. Get estimated PPM out of spec, the sigma level, and a normal capability curve with your spec limits and out-of-spec tails shaded. Capable, marginal, and not-capable industry examples.

Map a process at a glance across Suppliers, Inputs, Process, Outputs, and Customers — the standard Define-phase tool for scoping a Six Sigma or improvement project. Editable columns, process boundaries, manufacturing and healthcare examples, and print-ready export.

Track plan vs actual output every hour at the line. Enter takt to auto-calculate the hourly plan, log actuals and reason codes, and watch a cumulative pace line and a live loss Pareto build. Print your own production analysis board.

Calculate Overall Equipment Effectiveness from availability, performance, and quality inputs. Identify your biggest loss category and get actionable improvement guidance.

Calculate takt time from available time and customer demand. Add workstations to compare cycle times against takt with a visual bar chart — find bottlenecks and balance your line.

Score your workplace across Sort, Set in Order, Shine, Standardize, and Sustain. 25-item manufacturing checklist with radar chart, action items for low-scoring areas, and print-ready export.

Size a pull-system replenishment loop from daily demand, lead time, container quantity, and safety factor. Shows cards, max WIP, and days of supply.

Estimate setup reduction impact from current and target stopped time. Calculates time saved, capacity gained, and annual value.

Calculate Every Part Every Interval for mixed-model production. Estimate run time, setup capacity, and lot quantities by part family.

Stack each operator's work against takt time, spot overburden, and calculate the theoretical minimum operators. Drag elements to rebalance. Free Excel template included.

Build a complete one-page A3 with guided sections — background through follow-up. Print at true A3 landscape. Free Excel template included.

Map team skills with Toyota-style quadrant circles. Spot coverage gaps and single-point risks, and plan cross-training. Free Excel template included.