Manufacturing
Warehouse picking spaghetti diagram template
An example warehouse layout · Numbered picking stops and route arrows · Space to discuss movement and changes
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Shop-floor diagrams for lean manufacturing and logistics teams, from gemba walks and huddle boards to cell layouts and value streams.
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Manufacturing
Manufacturing value stream map template
Supplier, process and customer flow · Inventory queues and process data · Information flow and timing line
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Manufacturing
Gemba walk route and observation board template
Floor plan with a numbered walk route · Look, seen and ask notes at every stop · Walk standard and after-the-walk checklist
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Manufacturing
5S audit checklist board template
Tickable audit questions for each S · Score grid by area and pillar · Action cards with owner and due date
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Manufacturing
Machine downtime fishbone diagram template
6M fishbone with three causes per bone · Downtime effect stated with hours lost · Evidence list and next test with an owner
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Manufacturing
Warehouse layout plan template
Floor plan with docks, racking and work areas · Flow arrows and a replenishment route · Size checks and a sign-off checklist
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Manufacturing
8D problem solving report template
Nine panels from D0 to D8 · 5 whys root cause and action table · Validation chart and closure record
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Manufacturing
SQDC huddle board template
Safety cross for the month · Quality, delivery and cost charts by day · Issues and actions table with escalation
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Manufacturing
8 wastes of lean (TIMWOODS) waste walk template
Eight tiles for TIMWOODS · Shop-floor example under each waste · Finding notes and a tally after the walk
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Manufacturing
SMED changeover analysis template
Before timeline with each step timed · After swimlanes for internal and external work · Before and after results table
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Manufacturing
OEE six big losses tree template
Tree from OEE to the six big losses · Example cause under each loss · Minutes-lost chart and the OEE calculation
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Manufacturing
Kaizen event plan template
Five-day agenda from scope to standardise · Team roles and time commitment · Baseline, target and actual measures
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Manufacturing
Kaizen newspaper action tracker template
Problem and countermeasure for each line · Owner and due date columns · PDCA progress squares and newspaper rules
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Manufacturing
Inbound receiving process flowchart template
Four swimlanes from carrier to inventory · ASN and damage decisions with Yes and No paths · Data to record at receipt
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Manufacturing
Pick, pack and ship swimlane diagram template
Lanes for WMS, picker, packer and dispatch · Short-pick and weight-check decisions · Data handoff for the carrier manifest
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Manufacturing
U-shaped cell layout template
Before and after floor layouts · Operator walk routes and in and out points · Comparison table and pre-move checks
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Manufacturing
Production planning gantt chart template
Gantt of work orders by line and day · Changeover, maintenance and milestone rows · Capacity table and scheduling rules
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Manufacturing
Two-bin kanban system diagram template
Replenishment loop from bench to stores · Reorder decision and supplier trigger · Kanban card fields and bin sizing
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Manufacturing
Defect Pareto chart and 5 whys template
Pareto bar chart and cumulative table · 5 whys ladder from problem to root cause · Countermeasure and a check of the cause
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Manufacturing
PICK chart for improvement ideas template
Payoff and effort axes with four quadrants · Example kaizen ideas as sticky notes · Scoring guide and next step for each quadrant
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