Continuous Improvement Toolkit
for Business and Life!
Lean Tools Guide
Yellow Belt Guide
Green Belt Guide
Black Belt Guide
DMAIC Process Guide
Basic Quality Tools
A Standard Work Chart is an example of a visual standard work document. It is used to help with the layout and arrangement of your operation.
This is an example of a template that can be used to document your standard operating procedure (SOP) for any of your business processes.
This example illustrates an SOP which was created for the label changeover process in a manufacturing facility.
This is an example of an SOP which was created for the order process in a service environment.
Customer observation forms can be used to truly understand the viewpoint of customers and how they experience your products and services.
Process observation forms can be used to record the observed data, interview responses, improvement opportunities, and any other useful information.
Example of visual management in a production line. 1. Safety sign 2. Andon lights 3. Floor marking 4. Machine identity 5. Visual instructions 6. Gauge marking.
Safety visuals often use bright coloring to attract attention.
Floor marking is used to improve the layout of the workplace and mark critical safety and security areas.
Pipe marking communicates all the necessary information about the pipelines including the content, direction and flow rate. Arrows are used to indicate the flow direction while colors often indicate the nature of the content.
Andon lights are powerful visual tools which are installed on production machines to indicate their current status. They are very useful in bringing immediate attention to problems as soon as they arise.
A restaurant team has constructed a why-why diagram to resolve a complaint regarding the increased number of customer complaints about the taste of the coffee they make.
This 5 Whys example is often used during our Lean Six Sigma workshops. Notice the difference between the assumed cause and the root cause.
In this example, a team used the 5 Whys approach to determine the reason behind a customer complaint about the delayed test results at a laboratory. Only four Whys were required to get to what looks to be the root cause.
This is an example that uses the 5 Whys approach to answer a concern during a Lean Six Sigma workshop. Note that you can carry on asking Why and ask, “why doesn’t maintenance department have a schedule for routine activities?”.