Free tools for Lean manufacturing
Measure your process. Find the loss. Fix it.
Interactive calculators and practical guides for process engineers, production managers and continuous improvement teams – built from real shop-floor experience.
Built from shop-floor practice
Every guide comes from real improvement work in manufacturing.
Verified formulas
Standard definitions and a worked example in every article.
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Most used
Start with the essentials
Six tools that answer the questions every production team asks first: how fast, where it stops and what it costs.
OEE Calculator
Measure availability, performance and quality in one score.
Open toolTakt Time Calculator
Find the pace of customer demand and compare it with cycle time.
Open toolBottleneck Analysis
Identify the process that limits your line’s output.
Open toolPareto Chart Calculator
Find the vital few causes behind most of your losses.
Open toolSMED ROI Calculator
Turn shorter changeovers into hours of capacity and money.
Open toolSkills Matrix Calculator
Check whether your team can cover absences and peaks.
Open toolBottleneck Factory: learn Lean by playing
Line 3 ships 40 windows an hour and customers want 80. Chase the moving bottleneck through five episodes, classify the wastes on the Gemba walk and earn a grade from C to S.
All 27 tools
Browse by topic
Every tool comes with a step-by-step guide and a worked example.
Lean & Flow
11 tools- Takt Time CalculatorFind the pace of customer demand and compare it with cycle time.
- Bottleneck AnalysisIdentify the process that limits your line’s output.
- Value Stream MappingCalculate Process Cycle Efficiency and spot waiting time.
- Kanban CalculatorSize a pull loop from demand, lead time and container size.
- Line BalancingLine efficiency, balance delay and minimum stations.
- Little’s LawLink WIP, throughput and lead time in one formula.
- Heijunka CalculatorLevel volume and mix into a repeating daily pattern.
- SMED ROI CalculatorTurn shorter changeovers into hours of capacity and money.
- Standardized WorkHow many operators your process needs at takt.
- 5S Audit Checklist25-question audit with instant score per S.
- Spaghetti DiagramTurn walking paths into hours and money.
Quality & Problem Solving
7 tools- Pareto Chart CalculatorFind the vital few causes behind most of your losses.
- Cpk CalculatorProcess capability Cp, Cpk and ppm out of spec.
- First Pass YieldFPY per step and rolled throughput yield.
- Cost of Poor QualityScrap, rework and warranty cost as % of sales.
- FMEA RPN CalculatorScore severity, occurrence and detection.
- 5 Whys WorksheetDrill down from symptom to root cause.
- Fishbone DiagramStructure possible causes with the 6M.
OEE & Maintenance
4 toolsPeople & Change
5 tools- Skills Matrix CalculatorCheck whether your team can cover absences and peaks.
- ADKAR AssessmentFind the barrier point of a change.
- Change Readiness CheckSpot the gaps before you launch a change.
- Kaizen ROI CalculatorPayback of a kaizen event in months.
- Gemba Walk Checklist20 questions and an instant follow-up list.
No tool matches. Try “OEE”, “takt” or “quality”.
Where to start
A simple path through the toolkit
New to Lean metrics? Follow these four steps in order.
Latest guides
Practical guides from the shop floor
New guides on process data, Lean tools and change management.
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Lean Six Sigma Green Belt vs Black Belt: Which One Should You Choose?
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Control Plans: How to Make Process Improvements Stick
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Cpk & Process Capability Deep Dive: Cp, Cpk, Pp and Ppk Explained
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DMAIC in Practice: Reducing Scrap in Extrusion Lines
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Practical Six Sigma & DMAIC Framework: A Step-by-Step Guide for Manufacturing Engineers
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Remote Process Data Analysis: Find Hidden Losses Without a Site Visit
About Process Lab Pro
An independent project run by a process change manager working in manufacturing. One goal: turning Lean theory into numbers you can act on tomorrow morning on the shop floor.