Free templates
Free lean manufacturing templates
Ten printable templates for the lean methods teams use every week: a 5S audit checklist, a gemba walk checklist, an A3 problem solving sheet, a PDCA sheet, a 5 Whys worksheet, an 8D report, a skills matrix, a standard work sheet, a SMED changeover worksheet and a kaizen event charter. Each page explains what the template is, when to use it and how to fill it in, with a worked example and the mistakes to avoid. Download the PDF, or the Excel version where there is one.
5S audit checklist template
25 checks, five per S, scored 1 to 5, with a score summary and a chart of the five S's.
- Excel
Gemba walk checklist
A walk plan and route, 30 prompts in six groups and a findings table with owners and due dates.
- Excel
A3 problem solving template
The standard seven-box A3 on one landscape sheet, from background to follow-up.
PDCA template
One improvement cycle on one landscape page: plan, do, check against the goal, then standardize or adjust.
5 Whys template
A problem statement, five why rows with evidence, the root cause and the countermeasure.
8D report template
D0 to D8 on three pages: team, is/is not, containment, occurrence and escape causes, actions and closure.
Skills matrix template
People by skills, a 0 to 4 scale, a training column and a coverage row that shows the gaps.
- Excel
Standard work sheet template
Takt time, each element's manual, machine and walk time on a time chart, key points and standard WIP.
- Excel
SMED changeover worksheet
Changeover steps with times, internal or external, what can move, ideas and before/after totals.
- Excel
Kaizen event charter template
Scope, team and roles, baseline and target metrics, a five-day schedule, risks and sign-off.
Lean Studio boards
30 ready-made boards in Lean Studio
The same lean methods as whiteboards inside LeanSuite: stickies, shapes, arrows and live data widgets on one board. Each board has a page with what it is for, what is on it and a sample with data. What Lean Studio is.
Problem solving
From a symptom to a root cause and a countermeasure
Process & flow
See a process end to end and where it waits
Daily management
Tier boards, huddles, audits and plan-vs-actual
Improvement & ideas
Collect, sort and prioritize improvement ideas
Team & strategy
Strategy deployment, retrospectives and skills
Use these boards in LeanSuite
The boards live inside LeanSuite. Try the interactive demo in your browser, or pilot LeanSuite on your own lines for 90 days.
Made to be printed, filled in and reused
Print-ready PDFs
Every template is a clean PDF sized for Letter paper that also prints on A4. Take it to the floor on a clipboard.
Excel where it helps
The 5S audit checklist, gemba walk checklist, skills matrix, standard work sheet and SMED worksheet also come as spreadsheets that do the sums for you.
Free, for a work email
Enter your name and work email once and every template downloads straight away. No account, no payment.
Free to use
All ten templates are free to use. Download them, print them and edit them to fit your area. To download, enter your name and work email once; there is no account to create.
Need a number rather than a form? The free lean calculators work out OEE, takt time, changeover savings and more, and the lean glossary defines the terms these templates use.