Tools

GEMBA Walk. Use our GEMBA walk sheet to help prepare, conduct and create action plans to address waste opportunities your team identifies on a GEMBA walk.

GEMBA Walk_BC

Hoshin Planning. Use this tool to help your team prioritize projects and performance targets based upon your strategic objectives.

Lean Methods Group_XMATRIX_hoshin_policy_deployment_templates

Lean Assessment. This scorecard approach helps leadership teams assess their current level of ‘lean’ in order to set their teams up to prioritize and move in a more lean direction.

Lean Site Assessment_BC

RACI – Responsible, Accountable, Consult and Inform This tool is used to help teams document roles and responsibilities for process and project stakeholders.

RACI template_BC

TAKT time and Workload Balance This simple tool can be used to calculate TAKT time and also look at your processes to see if each step meets the TAKT time required. Also included is a description of TAKT time vs Cycle time, as they are not the same.

TAKT time Work Load Balance Chart_BC

Value Stream Mapping Charter This charter template is helpful to ensure stakeholder support, agreement on the main scope to be addressed by the value stream mapping event and the team involved, both in the event and as ‘on call’ experts.

VSM Charter Template_BC

Value Added Cycle Time Analysis tool. This tool allows you to analyze your entire process, evaluating each process step for its cycle time and whether the step is value adding, value enabling or not value adding.

value added cycle time analysis spreadsheet_BC

Time Observation Sheet. This spreadsheet is used to collect cycle time data.

TimeObservationForm_BC

Kanban assessment. Use this tool to calculate Kanban quantities to set up your Kanban system.

Kanban Card Calculations_BC

Kaizen Event Planning Sheet Use this planning sheet to develop and execute a Kaizen event.

Kaizen Planning Template_BC

Action Tracker This project management tool is a simple alternative to Microsoft project or other advanced project planning tools. It is used as a Kaizen newspaper action tracker or a simple project tracker for any type of project.

Action Tracker_BC

Radar Diagram Use this diagram to rate, with a group of people, your current capabilities on a scale of 1-5. A quick to deploy tool, it can be used at the beginning of a Kaizen event to build a common understanding of the current or desired future state.

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Project Charter.  Use our project charter format to describe the scope, goals, team and timeframe of the problem you are targeting to solve through the use of the powerful DMAIC Lean Six Sigma methodology.  There are two formats of this file, one is in WORD and the other in POWERPOINT.

Lean Six Sigma Project Charter Template PPT_BC

Lean Six Sigma Project Charter Template WORD_BC

Net Promoter Score. Use the net promoter score to determine your customers’ loyalty to your product/service.  Included in this short module is a description of what is Net Promoter Score along with how to use it to quantify and qualify Voice of Customer.

Net Promoter Score_BC

SIPOC. Use this powerpoint template to document your high level process map on one page.

SIPOC Template with Charter_BC

Hoshin Deployment Matrix. The purpose of the Hoshin Kanri X Matrix Template for Lean Policy Deployment is to develop and implement plans that are strategic, tactical, and coordinated across people across the organization. The X-Matrix also ensures there is ownership at all levels and accountability, encourages organizational learning, faster course corrections, and cross departmental coordination. Hoshin means “Shining Metal Pointing Direction” in other words, it’s a compass that points to True North for your organization.  This template was developed by The Lean Methods Group and can also be found on their website.  https://www.leanmethods.com/

Lean Methods Group_XMATRIX_hoshin_policy_deployment_templates

Balanced Scorecard. The balanced scorecard is a top-down approach that establishes the organization’s vision and strategy using metrics that address each of these four areas to link objectives: Customer Perspective, Financial Measurements, Internal Business Operations, Learning and growth.

Balanced Scorecard Template and Example_BC

Stakeholder Analysis. This excel template can be used to document the project’s stakeholders, their current level of support and the desired level of support required for the project’s success.

Stakeholder Analysis Template_BC

CTQ or Cause & Effect Matrix. Use this matrix to relate your customers’ CTQ’s to your processes’ or potential solutions. The output is a rating which will help your team to prioritize where to start your improvement effort or to implement your solution.

CTQ Matrix_BC

Cause and effect matrix Template_BC

Project CTQ and Voice of the Customer Data Collection Requirements. Use this word-based template to work with a team to identify the customer and the data required in order to document the customers’ Voice, known as VOC.

Project CTQ and VOC data collection requirements_BC

Selecting Y Checklist.  Selecting the proper Y (output) variable for your process is not necessarily simple. Use this template with your team to determine the best possible Y metric for your project, based upon key criteria which are outlined in the checklist.

Project Y Checklist_BC

Sample Size Calculator.  Use this tool to determine the appropriate sample size based upon your data collection requirements.

sample size calculator_BC

Data Collection Plan.  Every data collection effort should be accompanied by a data collection plan which you will use to think through the data required as well as the methods to collect the data.  Use this data collection plan to ensure you have documented the most important elements of this effort.  Additionally, use the template to work through your measurement system analysis requirements and document the results of your MSA Study.  The data collection plan checklist is a useful tool to ensure you have evaluated your plan against best practice methods to ensure you collect data which are reliable, and which properly reflect the process you are attempting to characterize.

Data collection worksheet and measurement systems analysis_BC

Six Sigma Calculator for Discrete Data.  Use this excel-based template to calculate Sigma Values to indicate how capable your process is of delivering defect-free products and/or services.

Calculating Sigma Values for Discrete Y_BC

Improvement goal.  Use this template to document your improvement goal which is the last deliverable in the measure phase.

Improvement Goal_BC

Data Plan Communication template.  Use this template to document a communication plan which can be used as you communicate any of the key Lean Six Sigma deliverables, project results or plans to collect data or implement solutions.

Data Collection Communication Plan_BC

Minitab Cheat Sheet.  This complete presentation gives an introduction to Minitab software so that users can build from no knowledge to grow their understanding of how to use this powerful tool.  Included are cheat sheets for each tool utilized in Minitab, cross referenced to relate to the Six Sigma data or tool requirement.

Minitab Introduction with Cheat Sheets_BC

Z Tables.  This file shows the Z tables and allows users to calculate their probability of a defect (P(d)), DPMO or Yield given different Z values.

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Control vs impact matrix.  This simple matrix, in powerpoint format, can be used by your team to determine and demonstrate which of all of the X’s (root causes) contribute the most to your Y (output) measurement and directly affect your customers’ Critical to Quality (CTQ) characteristics.

Impact vs control matrix to list all X's_BC

Cause and Effect (fishbone) Diagram.  Use this easy-to-input template to create a powerpoint chart documenting your team discussion focused on the cause(s) for failure or defect.  Two templates are provided. The first is focused on the 6M’s (Man, Method,  Materials, Mother Nature, Measurement and Means) and the second on Waste (using the DOWNTIME acronym).

Cause and Effect Diagrams-Fishbone Diagram Template_BC

Value Added/Cycle Time Analysis tool.  This excel-based tool enables the use of a Lean Technique designed to ascertain the percentage of your process which is Value-Adding, Value-Enabling, or Non-Value Adding.  Descriptions of each of these categories is included as are all calculations required to determine the appropriate percentages.

value added cycle time analysis spreadsheet_BC

FAILURE MODE & EFFECTS ANALYSIS (FMEA).  This excel-based template allows a team to document failure modes for potential or actual processes and services.  The team can use the tool to identify: What can Fail, How it Can Fail, Estimate Risk of Failure, Determine Effect of Failure, Evaluate Control Plans to Detect or Prevent Failure and Prioritize Actions to take.  The template also includes a section to document action taken and re-evaluate the risk of failure, known as the “Risk Priority Number or RPN”.

FMEA Template_BC

TAKT time and Work Balance Load Chart.  Use this excel-based template to generate a work balance load chart to determine which process steps have greater or smaller cycle times than what is required by the customer demand rate reflected in your TAKT time.

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GEMBA ‘Waste Walk’ worksheet.  Use this template to document waste in your GEMBA walks.  There are two files to consider.  One in PowerPoint and the other in excel format.

GEMBA Waste Walks PPT_BC

GEMBA Waste Walks excel_BC

Time observation tool. Use this template to collect data regarding process step cycle time.  The excel-based template provides columns for each process step in your value stream as well as ones dedicated to waiting or delay steps.  It also includes enough rows to ensure a minimum samples size of 10 units, each of which is observed as it travels through the value stream.

TimeObservationForm_BC

KANBAN calculation.  Use this template to determine advisable KANBAN quantities per container as well as the number of containers/cards required for your process to ensure proper flow without building excess inventory.

Kanban Card Calculations_BC

Beta Risk Calculator. Use this excel template to calculate alpha and beta risk given a certain sample size, mean, standard deviation and delta difference you are looking to detect.

Conducting a Kaizen Lean Event.  Use this excel-based template to prepare for your Kaizen Lean Event.  Included are each of the 3 phases of an event: Preparation, Event Facilitation and Post-Event Follow-up

  • Preparation: Pre-kaizen checklist
  • Facilitating the Event: Recommended agenda
  • Follow-up: Kaizen newspaper

Kaizen Planning Template_BC

Risk Assessment.  Use this excel-based tool to plan ahead for the implementation of a pilot, new product/service or improvement plan.  The tool documents a team’s discussion regarding risks that could negatively affect the project.  The template allows for the identification, prioritization and documentation of proposed abatement actions.

Risk Assessment_BC

Pilot Checklist.  Use the pilot checklist to think through how you will implement your pilot ahead of time in order to ensure you maximize your team’s energy and effort as they implement a piloted solution.

Pilot Planning and Analysis Template_BC

Sustained Solution and Pilot evaluation.  Use this evaluation form to document the results of your pilot, including both solution performance results as well as an evaluation of the pilot itself more broadly and of the learning achieved.

Pilot AND Sustained solution analysis sheet_BC

Developing the proposed solution.  This word document is designed to walk you through the ‘proposed solution’ deliverable.  It will help you think through your approach to the Improve phase, given the types of X’s you’ve identified, as well as provide a checklist to ensure the team properly evaluates solutions by using “Musts” and “Wants” criteria.

Developing the Proposed Solution_BC

Decision Making between alternate solutions.  This decision making matrix is used by leadership teams who are deciding which of alternative solutions to pursue. It requires a team of experts to evaluate solutions against 'must' criteria - which are minimal criteria which must be met to deliver the benefits to the customer and stakeholders against 'want' criteria - where the more of that criterion you have, the better the solution is. 

Wants vs Needs Decision Making Criteria Matrix

Control Plan.   Every Lean Six Sigma project must have a control plan to ensure that improvement is sustained and that there is accountability for ongoing continuous improvement efforts.  Ideally, the ‘process owner’ will own the control plan and ensure its recommended measurement and response plans are followed and reported to the value stream manager responsible to update leadership team(s) as well as the customer.

Control Plan template_BC

Sustain improvement checklist.  This checklist is used to document the final results of the project’s sustained solution.  It is used after the control plan has been implemented and the final solution has been implemented.

Sustained solution analysis sheet_BC

Project documentation checklist.  This checklist can be used to ensure the team gathers and communicates the required documentation to ensure future teams learn from the current project experience.

Project Documentation_BC

Radar Diagram.  The radar diagram is used to display several metrics at once for a particular (or multiple) value stream(s).  It can be used to assess what the next priorities should be for improvement effort.

Radar Diagram_BC

Six Sigma Reference Materials

  • Lean Six Sigma & Minitab: the Complete Toolbox Guide for all Lean Six Sigma Practitioners. By Quentin Brook.  Opex Resources LTD. 2014.
  • Lean Six Sigma for Service: How to use Lean Speed and Six Sigma Quality to improve Services and Transactions: Michael George. McGraw-Hill. 2003.
  • Applied Statistics for Business and Management using Microsoft Excel. Linda Herkenhoff and John Fogli.  Springer Science and Business Media. 2013.
  • Lean Six Sigma for Hospitals: Improving patient safety, patient flow and the bottom line. Jay Arthur.  McGraw-Hill 2016.
  • Lean Six sigma; A Tools Guide, 2nd edition. Murray Adams, Mark Kiemele, Lee Pollock and Tom Quan.  Air Academy Associates LLC. 2004.
  • Facilitator’s Guide …Facilitation at a Glance: Your Pocket Guide to Facilitation (Memory Jogger) by Ingrid Bens, GOALQPC and Janet MacCausland
  • 75 Icebreakers for Great Gatherings. Nan Booth.  Brighton Publications.  1999.

Lean Reference Materials

  • The Toyota Way.  Jeffrey K. Liker.  McGraw-Hill.  2004.
  • The Machine that changed the world. by James P. Womack, Daniel T. Jones and Daniel Roos. Free Press.  1990
  • The Goal. Eliyahu M. Goldratt and Jeff Cox  The North River Press Publishing Corporation.  4th edition 2014.
  • Lean Six Sigma: Combining Six Sigma Quality with Lean Speed: McGraw-Hill. 2002.
  • Lean Six Sigma for Service: How to use Lean Speed and Six Sigma Quality to improve Services and Transactions: Michael George. McGraw-Hill. 2003.
  • Lean Six Sigma for Hospitals: Improving patient safety, patient flow and the bottom line. Jay Arthur.  McGraw-Hill 2016.