Lean Manufacturing Toolkit

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Evaluate and promote best practices and optimum utilization of resources; devise standard operating practices and develop plans for the efficient use of materials, machines, capital and employees; and drive improvements through the application of lean manufacturing practices and Kaizen activity.

More Uses of the Lean Manufacturing Toolkit:

  • Initiate: participation and influence in review and execution of engineering change orders or deviations impacting material availability, material obsolescence, product configuration, product performance, and production throughput.

  • Confirm your organization ensures effective asset management to manufacturing and business processes and process flows applying Lean Manufacturing, Six Sigma, theory of constraints and other waste and variability reduction principles.

  • Manage work with local teams to continually drive improved operational performance as measured by key indicators from continuous improvement and through the application of lean manufacturing principles.

  • Utilize root cause problem solving skills to develop and lead implementation of continuous improvement, error proofing, ergonomics, yield, and other lean manufacturing initiatives for equipment and processes.

  • Encourage and maintain a safe work environment, support manufacturing processes with the utmost integrity and adherence to Quality policy, support site initiatives for Six Sigma, Lean Manufacturing and productivity improvements.

  • Systematize: coach and develop leaders from the front line to the leadership team on performing lean value streams through leadership culture and behavior changes, process operating rhythm, and method changes.

  • Help develop a culture based on Lean Manufacturing principles that continually strives for the most robust ways of doing things to service your customers and ensure the success of your organization.

  • Achieve production schedules and product requirements by applying lean manufacturing/synchronous principles with emphasis on variation reduction, control costs, and achieve productivity improvements.

  • Ensure your organization leads lean manufacturing initiatives to improve safety, reduce cycle times, improve productivity, improve process reliability, and improve customer satisfaction with respect to on time delivery and quality.

  • Support of manufacturing site requirements, leveraging spend across locations to identify and implement sourcing and process improvements to strengthen and accelerate supply chain initiatives.

  • Ensure your organization cross functional and cross organization partnership with product quality, manufacturing engineering, purchasing, sourcing, new product introduction, and logistics teams to support customer success.

  • Develop: coach key contributors on developing a highly effective daily management process focused on management through mission control, creation of flow, adherence to standard work, and solid implementation of rigorous problem solving.

  • Confirm your organization analysis of time and motion analysis, methods, estimating, process engineering and plant layout for assigned area to ensure balanced methods and available capacity to meet customer demand.

  • Manage policy deployment in the areas of Lean Manufacturing techniques, quality, cost reduction, complete and on time delivery, safety, customer satisfaction, employee relations, visual controls and plant performance measures.


Are your production processes set up to minimize waste. The Lean Manufacturing Toolkit addresses common challenges with best-practice templates, step-by-step work plans and maturity diagnostics for any Lean Manufacturing related project.

Using the toolkit effectively will save you and your staff many hours of R&D time in writing the questions and templates to obtain the results needed to analyse the data collected.




Download the Toolkit and in Three Steps you will be guided from idea to implementation results.

The Toolkit contains the following practical and powerful enablers with new and updated Lean Manufacturing specific requirements:

STEP 1: Get your bearings

Start with...

  • The latest quick edition of the Lean Manufacturing Self Assessment book in PDF containing 49 requirements to perform a quickscan, get an overview and share with stakeholders.

Organized in a data driven improvement cycle RDMAICS (Recognize, Define, Measure, Analyze, Improve, Control and Sustain), check the…

  • Example pre-filled Self-Assessment Dashboard to get familiar with results generation

Then find your goals...

STEP 2: Set concrete goals, tasks, dates and numbers you can track

Featuring 998 new and updated case-based questions, organized into seven core areas of process design, this Self-Assessment will help you identify areas in which Lean Manufacturing improvements can be made.

Examples; 10 of the 998 standard requirements:

  1. What main areas of difficulty can be identified in the current supply chain at the focal organization and in international manufacturing companies in general?

  2. Have you every wondered about whether lean manufacturing efforts are actually worth the cost in terms of labor time invested and shop floor changes?

  3. Are your manufacturing performance metrics aligned with your business objectives and key business improvement initiatives as Lean Manufacturing?

  4. Are there any statistics available that help represent what kind of return on investment manufacturers can expect in taking a lean approach?

  5. Does the world of large-scale, highly automated manufacturing have anything to offer to sophisticated software developers?

  6. How do the strategies implemented for manufacturing and quality control affect the cost accounting of your organization?

  7. What are the most significant factors that you see impacting manufacturer efficiency, either positively or negatively?

  8. How can things be structured so that the enterprise does nothing but add value, and does that as rapidly as possible?

  9. Where can manufacturing managers and supply chain managers look for techniques to improve manufacturing performance?

  10. Where do other organizations stand in terms of implementing and establishing a solid foundation of lean management?

Complete the self assessment, on your own or with a team in a workshop setting. Use the workbook together with the self assessment requirements spreadsheet:

  • The workbook is the latest in-depth complete edition of the Lean Manufacturing book in PDF containing 998 requirements, which criteria correspond to the criteria in...

Your Lean Manufacturing self-assessment dashboard which gives you your dynamically prioritized projects-ready tool and shows your organization exactly what to do next:

  • The Self-Assessment Dashboard; with the Lean Manufacturing Self-Assessment and Scorecard you will develop a clear picture of which Lean Manufacturing areas need attention, which requirements you should focus on and who will be responsible for them:

    • Shows your organization instant insight in areas for improvement: Auto generates reports, radar chart for maturity assessment, insights per process and participant and bespoke, ready to use, RACI Matrix
    • Gives you a professional Dashboard to guide and perform a thorough Lean Manufacturing Self-Assessment
    • Is secure: Ensures offline data protection of your Self-Assessment results
    • Dynamically prioritized projects-ready RACI Matrix shows your organization exactly what to do next:


STEP 3: Implement, Track, follow up and revise strategy

The outcomes of STEP 2, the self assessment, are the inputs for STEP 3; Start and manage Lean Manufacturing projects with the 62 implementation resources:

  • 62 step-by-step Lean Manufacturing Project Management Form Templates covering over 1500 Lean Manufacturing project requirements and success criteria:

Examples; 10 of the check box criteria:

  1. Procurement Management Plan: Are Lean Manufacturing project team roles and responsibilities identified and documented?

  2. Initiating Process Group: Have requirements been tested, approved, and fulfill the Lean Manufacturing project scope?

  3. Executing Process Group: How can software assist in procuring goods and services?

  4. Requirements Traceability Matrix: What percentage of Lean Manufacturing projects are producing traceability matrices between requirements and other work products?

  5. Quality Metrics: Is there alignment within your organization on definitions?

  6. WBS Dictionary: Can the contractor substantiate work package and planning package budgets?

  7. Probability and Impact Assessment: Does the software interface with new or unproven hardware or unproven vendor products?

  8. Procurement Audit: Are all claims certified by the officer giving rise to the claim (usually the purchasing agent)?

  9. Procurement Audit: Do all requests for materials, supplies, and services require supervisors authorization?

  10. Procurement Management Plan: Is the structure for tracking the Lean Manufacturing project schedule well defined and assigned to a specific individual?

Step-by-step and complete Lean Manufacturing Project Management Forms and Templates including check box criteria and templates.

1.0 Initiating Process Group:

  • 1.1 Lean Manufacturing project Charter
  • 1.2 Stakeholder Register
  • 1.3 Stakeholder Analysis Matrix

2.0 Planning Process Group:

  • 2.1 Lean Manufacturing project Management Plan
  • 2.2 Scope Management Plan
  • 2.3 Requirements Management Plan
  • 2.4 Requirements Documentation
  • 2.5 Requirements Traceability Matrix
  • 2.6 Lean Manufacturing project Scope Statement
  • 2.7 Assumption and Constraint Log
  • 2.8 Work Breakdown Structure
  • 2.9 WBS Dictionary
  • 2.10 Schedule Management Plan
  • 2.11 Activity List
  • 2.12 Activity Attributes
  • 2.13 Milestone List
  • 2.14 Network Diagram
  • 2.15 Activity Resource Requirements
  • 2.16 Resource Breakdown Structure
  • 2.17 Activity Duration Estimates
  • 2.18 Duration Estimating Worksheet
  • 2.19 Lean Manufacturing project Schedule
  • 2.20 Cost Management Plan
  • 2.21 Activity Cost Estimates
  • 2.22 Cost Estimating Worksheet
  • 2.23 Cost Baseline
  • 2.24 Quality Management Plan
  • 2.25 Quality Metrics
  • 2.26 Process Improvement Plan
  • 2.27 Responsibility Assignment Matrix
  • 2.28 Roles and Responsibilities
  • 2.29 Human Resource Management Plan
  • 2.30 Communications Management Plan
  • 2.31 Risk Management Plan
  • 2.32 Risk Register
  • 2.33 Probability and Impact Assessment
  • 2.34 Probability and Impact Matrix
  • 2.35 Risk Data Sheet
  • 2.36 Procurement Management Plan
  • 2.37 Source Selection Criteria
  • 2.38 Stakeholder Management Plan
  • 2.39 Change Management Plan

3.0 Executing Process Group:

  • 3.1 Team Member Status Report
  • 3.2 Change Request
  • 3.3 Change Log
  • 3.4 Decision Log
  • 3.5 Quality Audit
  • 3.6 Team Directory
  • 3.7 Team Operating Agreement
  • 3.8 Team Performance Assessment
  • 3.9 Team Member Performance Assessment
  • 3.10 Issue Log

4.0 Monitoring and Controlling Process Group:

  • 4.1 Lean Manufacturing project Performance Report
  • 4.2 Variance Analysis
  • 4.3 Earned Value Status
  • 4.4 Risk Audit
  • 4.5 Contractor Status Report
  • 4.6 Formal Acceptance

5.0 Closing Process Group:

  • 5.1 Procurement Audit
  • 5.2 Contract Close-Out
  • 5.3 Lean Manufacturing project or Phase Close-Out
  • 5.4 Lessons Learned



With this Three Step process you will have all the tools you need for any Lean Manufacturing project with this in-depth Lean Manufacturing Toolkit.

In using the Toolkit you will be better able to:

  • Diagnose Lean Manufacturing projects, initiatives, organizations, businesses and processes using accepted diagnostic standards and practices
  • Implement evidence-based best practice strategies aligned with overall goals
  • Integrate recent advances in Lean Manufacturing and put process design strategies into practice according to best practice guidelines

Defining, designing, creating, and implementing a process to solve a business challenge or meet a business objective is the most valuable role; In EVERY company, organization and department.

Unless you are talking a one-time, single-use project within a business, there should be a process. Whether that process is managed and implemented by humans, AI, or a combination of the two, it needs to be designed by someone with a complex enough perspective to ask the right questions. Someone capable of asking the right questions and step back and say, 'What are we really trying to accomplish here? And is there a different way to look at it?'

This Toolkit empowers people to do just that - whether their title is entrepreneur, manager, consultant, (Vice-)President, CxO etc... - they are the people who rule the future. They are the person who asks the right questions to make Lean Manufacturing investments work better.

This Lean Manufacturing All-Inclusive Toolkit enables You to be that person.