Training Within Industry
- Improvement Proposal Sheet
- Job Instruction Training Timetable
- Job Breakdown Sheet 1
- Job Breakdown Sheet 2
Quick Learning Modules
- QCO Quick Learning Module– .ppt file –
- 5S Quick Learning Module– .ppt file –
Lean Value Stream Assessment Tool
- Lean Assessment with Graph v1.1 – .xls file (direct download)
- Lean Value Stream Assessment Tool Description (Instructions) – .doc file (direct download)
5-S Overview
Value Stream Mapping
- Value Stream Map Diagram
- Value Stream Map Diagram (Sample)
- Value Stream Map Diagram (Blank)
- Formulas for VSM Calculations – .doc file (direct download)
Quick Changeover
- Setup Observation Sheet – Blank – .xls file (direct download)
- Setup Observation Sheet Sample
- SMED Techniques
Cellular Flow
- People/Product Flow Worksheet – .xls file (direct download)
- Cellular Manufacturing – .ppt file (direct download)
- Product Family Matrix (blank) – .xls file (direct download)
- Time Observation – .xls file (direct download)
- Process Capacity Table (blank) – .xls file (direct download)
- Set up Observation Sheet – .xls file (direct download)
- Standard Work Content Chart – .xls file (direct download)
- Standard Work Combo Sheet – .xls file (direct download)
Total Productive Maintenance
- Operational Effectiveness Spread Sheet – .xls file (direct download)
- OEE Worksheet– .xls file (direct download)
- OEE Data Collection Form with Times – .xls file (direct download)
Pull Systems
(.zip files)
- Demand Analysis for Supermarket Design System
- Plan for Every Part Worksheet
- Sizing Spreadsheet for internal supermarkets
- Sizing Spreadsheet for Purchased parts
- Standard Supermarket Reorder Analysis
- Supermarket Sizing Table with EPE calc
Toyota Kata Program
Strategic Planning
- ISI Strategy deployment matrix template v 2 – .xls file (direct download)
Lean Supply Chain Logistics
- View Scorecard on the Web
- Interactive Lean Assessment Scorecard – .xls file (direct download)
Project Facilitation Skills
- Pilot Project Checklist
- Appendix Document List
- Line Balancing and Cell Layout
- Labor Linearity Chart
- Process Flow Worksheet
- Process Capacity Table – .xls file (direct download)
- Plan for Every Part Worksheet – .xls file (direct download)
- Workplace Scan Checklist
- Waste Observation Form
- Supermarket Sizing Problem Narrative
- Supermarket Sizing – .xls file (direct download)
- Takt Time Illustration – .xls file (direct download)
- Standard Work Content Chart – .xls file (direct download)
- Lean Implementation Project Planner
- Project Scope Statements
Post Project Reporting
- Debugging Checklist – .doc file (direct download)
- Implementing Tips – .doc file (direct download)
- Standard Performance Chart for Kaizen Event – .doc file (direct download)
- Kaizen Report Out Format in PowerPoint (direct download)
- Certification Kaizen Event Form – .xls file (direct download)
_____________________________________________________________
Lean Implementer Homework Assignments
1. After Month 1, due by Wednesday of the 2nd month:
Draw a Current State Value Stream Map & an Operator Balance Chart of a process at your company. It should be at least 3 manufacturing processes long. Be sure to show your Takt Time calculation, the Total Lead Time and Value Added Ratio.
2. After Month 2, due by Wednesday of the 3rd month:
Fill out a Job Methods Analysis Worksheet on a work process (should be 10 steps or more). Put in as much detail as possible on the form. Two examples are on the additional tabs for reference.
Month 2 JM Breakdown Worksheet – .xls file (direct download)
3. After Month 3, due by Wednesday of the 4th month:
ISI VSM Problem –map and calculations based on the data set given. Show the Takt Time calculations, Total Lead Time, and Value Added Ratio. Draw an Operator Balance Chart.
Next, for a 2-week period, in cooperation with a machine operator, calculate the OEE percentage. A OEE Data Collection Form is provided, and use the findings to calculate the OEE using the OEE Worksheet.
Month 3 INITECH VSM Homework – .pdf file (to download: right-click, Save Link As)
Month 3 OEE Data Collection Form – .xls file (direct download)
OEE Worksheet– .xls file (direct download)
4. After Week 4, due by Monday of the 5th month:
Calculate the parameters for a pull system using the Supermarket Sizing Spreadsheet provided. Fill in the Data tab if the information is available. Run the calculations for 5-10 parts.
Month 4 Supermarket Spreadsheet – .xls file (direct download)