Free lean toolkit · DF Consulting
Seventeen tools. No license, no login, no consultant required.
The sheets I actually use on the floor — OEE, takt and line balance, 5S, changeover reduction, value stream data, skills coverage. Every one of them runs right here in your browser and does the arithmetic as you type. Every one of them also downloads as a Word or Excel template for the people who would rather work on paper.
Start with the problem
What is actually going wrong?
Pick the one that sounds like your week and the toolkit filters itself to the two or three tools worth reaching for, in the order they work.
The toolkit
All seventeen
A3 Problem Solving Report
Carry one problem from background to standardized fix on a single page.
Root Cause Analysis
5 Why chain with an evidence test on every link, plus the 6M fishbone.
PDCA Cycle Sheet
One improvement experiment: predict, run, compare, decide.
DMAIC Project Charter
Scope, measures, team and tollgates, signed before the project starts.
5S Audit Scorecard
25 items across the five pillars, scored live with a pillar breakdown.
Standard Work Combination
Manual, machine and walk time for one cycle, measured against takt.
TWI Job Breakdown
Important steps, key points and the reason behind each one.
Layered Process Audit
Ten short checks by layer, scored, with findings that carry an owner.
Value Stream Map Data
Lead time, value-adding time and process cycle efficiency from your own numbers.
Spaghetti Diagram
Draw the travel on screen and get the distance per shift as you go.
Takt and Line Balance
Takt from demand, station loading against it, and where the work is stacked.
SMED Changeover Study
Split internal from external, convert what you can, score the reduction.
Tiered Huddle Board
SQDCP for the week, the action list, and what escalates today.
Kamishibai Cards
Six standing checks. Green face out means it passed today.
OEE Calculator
Availability, performance and quality by shift, with the loss that caused it.
Gemba Walk Sheet
The same five questions every walk, the eight wastes, and what you committed to.
Skills Matrix
Who can run what, and which jobs stand one absence away from a stoppage.
Nothing matches that. Try a different word, or clear the filter.
How to use them
Three rules that apply to all seventeen
Fill it in where the work happens
With the people who do it, not about them. A form filled in at a desk is a form that lies, and everyone on the floor can tell which is which.
A number with no owner is not an action
Every tool here ends in the same place: something specific, someone named, a date. The arithmetic is the easy part.
Stop using what stops earning
If a board has gone stale or an audit has become theater, retire it. The tool was never the point.
What happens to what you type
Nothing leaves your browser. Every sheet saves to this device only, so you can close the tab and come back to it, and clear it whenever you like. There is no account, no tracking of your entries, and nothing is sent anywhere. Print any sheet to PDF when you want a copy to hand round.