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Lean principles assessment template
A lean principles assessment checks how far each of the five lean principles shows on one value stream or area today, from what you can see on the floor rather than from opinions. The five principles, set out by James Womack and Daniel Jones in Lean Thinking, are worded here as in the lean principles guide on this site: define value, map the value stream, create flow, establish pull and seek perfection. Under each are five things you can check on a walk, such as a current state map drawn in the last 12 months or upstream steps that start work only on a signal. Each is answered yes, partly or no, with what you saw. Page 1 is the walk sheet; page 2 has the score per principle with the next step and the templates on this site that help, a table for repeat walks and a worked example. The Excel version holds up to 6 walks of the same value stream, counts yes, partly and no, scores each principle, shows the latest walk against the first with the lowest principle, and charts the scores by principle and over time. The score is (yes + half of partly) ÷ items answered, a simple example rule made for this template, not a maturity standard.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for value stream, walked by, date and walk number, the yes, partly and no key, and 25 items under define value, map the value stream, create flow, establish pull and seek perfection, each with Y P N circles and a what you saw column, and a score cell per principle.5 lean principles25 things to seeYes, partly, noWhat you sawScore per principleNext step per principleRepeat walksTrend
When to use it
When to use a lean principles assessment
- On a value stream that has started lean work, to see which principle is furthest behind and pick the next step.
- Before and after a value stream mapping project, to check that the future state is showing on the floor.
- As a quarterly walk with the value stream manager, to track progress on the same 25 items over time.
- To compare two value streams or areas walked the same way, and learn from the one further ahead.
How to fill it in
- 1
Pick one value stream
One product family or area from order to delivery, with a named owner. A whole plant on one sheet averages away the gaps.
- 2
Walk it, do not ask about it
Two or three people walk the value stream together. Mark each item yes, partly or no from what you can see or check today, and write what you saw: where, how many, an example.
- 3
Score each principle
Count the yes, partly and no answers. Score = (yes + half of partly) ÷ items answered. Leave out items you could not check rather than guessing.
- 4
Choose the next step
Start with the lowest principle, or with the one the next depends on: pull needs flow, and flow needs a map. Page 2 names the templates on this site for each principle, from the value stream map to the kanban sizing calculator.
- 5
Walk again
Walk the same value stream every two to three months with the same items and rule, and copy the scores into the trend table to see what moved.
What's on the walk
The 25 things to check on the floor, five for each lean principle
On a walk of one value stream, each item is answered yes, partly or no from what you can see today, with what you saw. The principles are worded as in the lean principles guide on this site.
Define value
What the customer needs and pays for
- 1The customer's requirements for this value stream (quantity, delivery, quality) are written where the team can see them
- 2Daily demand or takt time for this value stream is known and posted
- 3Recent customer complaints and returns for these products are shown in the area
- 4Operators can say what the customer needs from the step they work on
- 5Work the customer does not need (rework, extra checks, reports nobody reads) has been listed
Map the value stream
Every step from order to delivery, seen as one flow
- 6A current state map of this value stream exists, drawn from a walk in the last 12 months
- 7The map shows inventory between steps and lead time against value-added time
- 8A future state map exists with a plan, an owner for each action and dates
- 9One person is responsible for the whole value stream, not only for each department in it
- 10Inventory on the floor between steps is close to what the map shows
Create flow
Value-adding steps run without stops, piles or waiting
- 11Parts move to the next step one at a time or in small batches, not in large piles
- 12Inventory between steps has a set maximum (marked lanes or FIFO lanes) and it is kept to
- 13The bottleneck step is known and is not left waiting for material or people
- 14Changeover times are measured and short enough to run small batches
- 15Work is balanced: no operator is clearly overloaded while another waits
Establish pull
Make what the customer has used, not what a forecast says
- 16Upstream steps start work only on a signal (kanban, empty bin, space in a FIFO lane)
- 17Kanban or supermarket quantities are worked out and posted, not guessed
- 18Finished goods stock has a set maximum based on customer demand
- 19The schedule goes to one point in the value stream only; the steps before it are pulled
- 20Material is replenished on a route or by a signal, without daily expediting
Seek perfection
Keep finding and removing waste, every day
- 21Problems in this value stream are logged and worked to a root cause, with an owner and a date
- 22Standard work is posted at the main steps and matches how the job is done
- 23The team reviews results against target every day at a board or huddle
- 24Improvements from the last three months can be seen, with a before and after
- 25Operators' improvement ideas get an answer, and some are in place
A filled-in example
Illustrative, not a benchmarkAn example: a bracket value stream (stamping, welding, painting and assembly) walked three times in 2026 by the value stream manager and the CI lead (illustrative numbers).
The five principles on the latest walk, in order
- 1Define value60%
- 2Map the value stream80%
- 3Create flow40%
- 4Establish pullLowest20%
- 5Seek perfection60%
Define value 60 percent, map the value stream 80, create flow 40, establish pull 20, seek perfection 60. Overall 52 percent, up from 24 in April and 40 in July.
- Latest walk, 29 September: define value 60%, map the value stream 80%, create flow 40%, establish pull 20%, seek perfection 60%.
- Establish pull: 0 yes, 2 partly, 3 no, so (0 + 2 ÷ 2) ÷ 5 = 20%, the lowest. Stamping runs to the weekly forecast and there is no kanban.
- Overall: 8 yes, 10 partly, 7 no: (8 + 10 ÷ 2) ÷ 25 = 52%.
- The overall score went from 24% in April to 40% in July and 52% in September, with the biggest gain in map the value stream (10% to 80%) once the current and future state maps were drawn.
The next steps were a supermarket of stamped brackets sized with the kanban sizing calculator, so welding pulls from stamping, and timing the press changeovers with the SMED changeover worksheet so stamping can run smaller batches.
Common mistakes
Scoring from the office
The items are things you can see. Answering them in a meeting turns the walk into opinions; go to the floor and write what you saw.
Assessing the whole plant at once
Value streams differ. One sheet per value stream shows where each one stands; a plant average hides the one that is furthest behind.
Jumping to pull before flow
Kanban on top of large batches and long changeovers usually fails. If flow and the map score low, work there first.
Changing the items between walks
The trend only means something if each walk uses the same items and the same rule. Add items for a new value stream, not halfway through.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
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FAQ
Lean principles assessment template: common questions
Define value from the customer's point of view, map the value stream, create flow, establish pull and seek perfection. They were set out by James Womack and Daniel Jones in the book Lean Thinking.
A walk of one value stream that checks how far each of the five lean principles shows on the floor. Each item is something you can see, answered yes, partly or no, and the answers give a score per principle and a next step.
For each principle, score = (yes + half of partly) ÷ items answered. Items you could not check are left out. This is a simple example rule made for this template, not a maturity standard, so use the same rule on every walk.
The lean readiness assessment asks whether the organization is ready to start lean, from several people's scores on leadership, culture, stability and engagement. This template checks how far each lean principle already shows on one value stream, from what you see on a walk.
Usually the lowest, but the principles build on each other: pull needs flow, and flow needs a map of the value stream. If the map scores low, start there even if pull scores lower.
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- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- TQM self-assessment templateThe eight TQM principles in 24 statements you can check on the floor, scored 0 to 4 by several people, with the spread, the top 3 gaps and an action plan.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.