Free tools
Free lean manufacturing calculators
The numbers lean teams work out every week: OEE, the cost of downtime, changeover time, takt, cycle and lead time, line balance, first pass yield, the cost of poor quality, process capability (Cp and Cpk) and MTBF with MTTR. Each shows its formula and a worked example, updates as you type, and gives you a link to share the result. The ROI calculator estimates what waste costs your plant, and the lean maturity self-assessment scores your lean system across nine dimensions. All free, with no sign-up.
Which tool for which problem
Start from the problem on your floor, then open the suggested tool.
- Machines stop or run slowAll 6 toolsStart withOEE calculator
- The line can't keep upAll 8 toolsStart withTakt time calculator
- Orders are slow, stock is highAll 4 toolsStart withLead time calculator
- Too many defects or scrapAll 6 toolsStart withFirst pass yield (FPY) calculator
- A problem keeps coming backAll 5 toolsStart withPareto chart maker
- Nobody knows what it costsAll 5 toolsStart withKaizen savings calculator
- People could get hurtAll 4 toolsStart withRisk matrix calculator
- Not sure where to startAll 2 toolsStart withLean method navigator
One problem, worked as a route: "the line can't keep up"
Machines stop or run slow
How much of the planned time your equipment makes good parts, what a stop costs, and how to maintain it.
OEE calculator
Start hereOverall equipment effectiveness from shift time, downtime, ideal cycle time and part counts.
- OEE
- Availability
- Performance
- Quality
TEEP calculator
Total effective equipment performance: OEE multiplied by how much of all calendar time you plan to run.
- TEEP
- Utilization
- OEE
- Unscheduled hours
Downtime cost calculator
What an hour, an event and a year of unplanned downtime cost, from lost output, idle labour, scrap and overtime.
- Cost per hour
- Cost per event
- Cost per year
MTBF and MTTR calculator
Mean time between failures, mean time to repair and availability from operating time, failures and repair time.
- MTBF
- MTTR
- Availability
Maintenance strategy selector
Answer the RCM questions for one failure mode and get the maintenance strategy, the reasoning and the check or test interval.
- Strategy
- Interval basis
- Reasoning
- Data to collect
Repair or replace calculator
Equivalent annual cost of keeping and repairing an old machine against buying a new one, with each one's economic life and the break-even figures.
- Equivalent annual cost of each
- Saving a year
- Economic life
- Break-even O&M and price
The line can't keep up
The pace demand sets, how each station and crew compares with it, and where the capacity is lost.
Takt time calculator
Start hereThe pace a line must hit to meet customer demand, from shift time, breaks and daily demand.
- Takt time
- Units per hour
- Available time
Cycle time calculator
Cycle time against takt, units per hour, capacity per shift and the gap to daily demand.
- Cycle vs takt
- Units per hour
- Gap to demand
Line balancing calculator
Line efficiency, balance delay and the minimum number of stations from station times and takt.
- Line efficiency
- Balance delay
- Minimum stations
Bottleneck calculator
The step that limits your line, from each step's cycle time, machines and uptime, with daily capacity and the gap to demand.
- Bottleneck step
- Line capacity
- Gap to demand
SMED changeover calculator
Time saved by moving changeover steps from internal to external, capacity freed per week and the smaller batch it allows.
- New changeover time
- Capacity freed
- Smaller batch size
Overall labor effectiveness (OLE) calculator
How well paid labor hours turn into good output: availability, performance and quality of the crew.
- OLE
- Availability
- Performance
- Quality
Time study sample size calculator
How many cycles of an element to time, from your first readings, with the t formula, the ILO formula and the range method.
- Cycles to time
- More cycles needed
- Accuracy so far
Shift schedule planner
Ten shift patterns on real dates: calendar for each crew, hours a week, weekends off, coverage and the weeks over 40 hours.
- Calendar per crew
- Hours per workweek
- Weeks over 40
- Weekends off
- Coverage check
Orders are slow, stock is high
How long work waits between steps, and how much stock you hold and need.
Lead time calculator
Start hereManufacturing lead time from WIP and throughput (Little's Law), and the share of it that adds value.
- Lead time
- Value-added ratio
- Non-value-added time
Throughput time calculator
Throughput time from process, inspection, move and wait time, the share of it that adds value, and units per hour.
- Throughput time
- Process cycle efficiency
- Throughput per hour
Inventory turnover and days on hand calculator
How many times stock turns over in a period and how many days of it you hold, from COGS and average inventory.
- Inventory turnover
- Days on hand
- Average inventory
Safety stock calculator
Safety stock and reorder point from the service level you want, average demand and lead time, and how much each varies.
- Safety stock
- Reorder point
- Z-score
Too many defects or scrap
Yield, scrap and what poor quality costs, whether the process can hold its tolerance, and how much to inspect.
First pass yield (FPY) calculator
Start hereFirst pass yield at each step and rolled throughput yield (RTY) across the whole process.
- FPY per step
- Rolled throughput yield
- Lowest step
Scrap rate calculator
Scrap rate, the cost of scrap per period and per year, and what reaching a target rate would save.
- Scrap rate
- Cost of scrap
- Saving at target
Cost of poor quality (COPQ) calculator
Total COPQ and cost of quality, and each as a share of revenue, from the four quality cost categories.
- COPQ
- % of revenue
- Cost of quality
Process capability (Cp, Cpk) calculator
Cp and Cpk against your specification limits, plus Pp and Ppk from pasted measurements, with a distribution chart.
- Cpk
- Cp
- Pp and Ppk
- Expected ppm out of spec
DPMO and sigma level calculator
DPMO, defects per unit, yield and sigma level from the defects found, units checked and opportunities per unit.
- DPMO
- Sigma level
- Yield
- DPU
Acceptance sampling calculator
Read the OC curve and the real risks of a sampling plan, find the plan for your AQL and LTPD, or size a zero-defect test.
- OC curve
- Producer's and consumer's risk
- Plan (n, c) from AQL and LTPD
- Zero-defect sample size
A problem keeps coming back
Paste your data or write down the causes, and get the chart or diagram to take to the team.
Pareto chart maker
Start herePaste categories and counts: sorted bars, cumulative percentage line and the vital few at the 80% line, as a PNG or SVG.
- Pareto chart
- Cumulative %
- Vital few
- PNG and SVG
Histogram maker
Paste measurements: the histogram with automatic or chosen bins, plus mean, median and standard deviation, as a PNG or SVG.
- Histogram
- Mean and median
- Standard deviation
- PNG and SVG
Box plot maker
Paste one or more groups of numbers: box plots with quartiles, IQR, whiskers and outliers by the 1.5 IQR rule, as a PNG or SVG.
- Box plot
- Quartiles and IQR
- Outliers
- PNG and SVG
Fishbone diagram maker
Name the problem, list causes under the 6M bones, and download the Ishikawa diagram as a PNG or SVG.
- Fishbone (Ishikawa) diagram
- Causes per category
- PNG and SVG
5 Whys canvas
Write the problem, answer up to five whys, state the root cause and countermeasure, then print the one-page canvas.
- Why chain
- Root cause
- Countermeasure
- Printable page
Nobody knows what it costs
What an hour of a machine, a unit or a leak costs, and what an improvement would pay back.
Kaizen savings calculator
Start hereYearly savings, payback in months and first-year ROI of an improvement, from time saved, scrap avoided and its costs.
- Annual savings
- Payback
- First-year ROI
Machine hour rate calculator
What one productive hour of a machine costs, with and without the operator, the cost per part and how utilisation moves the rate.
- Rate per hour
- Rate with labour
- Cost per part
- Cost breakdown
Total manufacturing cost calculator
Total manufacturing cost, cost of goods manufactured, cost per unit and the overhead rate from materials, labor and overhead.
- Total manufacturing cost
- Cost of goods manufactured
- Cost per unit
- Overhead rate
Compressed air leak cost calculator
Air lost, kW and cost a year for each tagged leak from its size and the pressure, ranked so the biggest gets fixed first.
- Air lost (cfm or L/s)
- kW wasted
- Cost a year
- Ranked repair list
Manufacturing ROI calculator
Answer a few questions about your shop floor, shifts and downtime to estimate your potential ROI with LeanSuite.
- Estimated annual waste
- Recoverable savings
People could get hurt
Incident rates, safe lifting and noise limits, and how to rank a hazard.
Risk matrix calculator
Start hereSeverity times likelihood on a 3 x 3, 4 x 4 or 5 x 5 risk matrix, the band and its action, editable banding, and the score after further controls.
- Risk score
- Risk band and action
- Score after controls
- Banding by grid size
TRIR and DART rate calculator
OSHA recordable and DART incident rates from your 300A case counts and hours, and what one more case does to them.
- TRIR
- DART rate
- Days-away rate
- One-case swing
NIOSH lifting equation calculator
Recommended weight limit and lifting index for a two-handed lift, with every multiplier shown so you can see what to redesign.
- Lifting index
- Recommended weight limit
- Six multipliers
Noise dose and TWA calculator
Dose and 8-hour TWA for a shift of noise levels under OSHA and NIOSH, which limits are reached and how much loud time to cut.
- Noise dose
- 8-hour TWA
- OSHA and NIOSH limits
- Time to cut
Not sure where to start
Answer a few questions and get the lean method to try first, or score where your lean system stands today.
Lean method navigator
Start hereSix questions about one problem, then the lean method to start with, the two that follow, why each fits, five steps for Monday and what it will not solve.
- Method to start with
- Why it fits
- Five steps for Monday
- Template to use next
Lean maturity self-assessment
Score 27 statements across nine dimensions and get a band for each, an overall band, where to start and the guides to read.
- Overall maturity
- Score per dimension
- Next steps
- Guides for low areas
Built to be checked, shared and reused
Formula and worked example
Every calculator here except the ROI calculator shows the formula it uses and a worked example you can check by hand.
Shareable results
Copy a link that opens the calculator with your numbers already in, or copy the result as text.
Free to embed
Put any of these calculators except the ROI calculator on your own site, course page or intranet with a short code snippet.
New to a term? The lean glossary defines OEE, SMED, takt time, cycle time, lead time, line balancing, COPQ, process capability, MTBF and more, and the Learn hub has the guides behind them. To put a dollar figure on the waste in your plant, try the LeanSuite waste and ROI estimate.
FAQs
Calculator questions, answered
They are free and need no sign-up: the result updates in your browser as you type. If you want a copy, you can email the result to yourself, and only the ROI calculator's full report asks for your work email.
Yes. Copy a link that opens the calculator with your numbers already filled in, copy the result as text, or email it to yourself from under the result.
Yes. Every calculator except the ROI calculator can be embedded on your site, course page or intranet with a short code snippet, free.
OEE is availability × performance × quality. Availability is run time over planned production time, performance is ideal cycle time × total count over run time, and quality is good count over total count. The OEE calculator at theleansuite.com/tools/oee-calculator shows each step with a worked example.
Takt time is the pace demand sets: available production time divided by customer demand. Cycle time is how long the line actually takes per unit. If cycle time is longer than takt, the line can't keep up without overtime or more capacity.
Yes. KPI dashboards track OEE, downtime, first pass yield and your own formula KPIs, with data from LeanSuite forms, your ERP or MES, Excel, Google Sheets or a CSV upload. A KPI is flagged red as soon as a value crosses its limit.
Next step
Working out the same number every week?
Bring it to a 45-minute demo and we will show where it fits in LeanSuite.