5S Workplace Organisation
Build a visual workplace standard, evaluate every 5S step and turn findings into a practical action plan.
LEAN Toolbox by Availix
30 interactive LEAN tools
Open a tool directly or read its practical method guide with inputs, workflow, calculations, examples, common mistakes and FAQs.
30All tools
Improve & Standardize
Kaizen Improvement Proposal
Structure a small improvement from current state through evidence, expected benefit, implementation tasks and follow-up.
PDCA Improvement Cycle
Plan an improvement hypothesis, record execution, compare actual results with the target and decide what to standardise or revise.
A3 Problem-Solving Report
Connect background, current condition, target, root-cause analysis, countermeasures and follow-up on one coherent management page.
Problem Solving & Quality
5 Why Root-Cause Analysis
Build an evidence-based cause chain from a precisely defined problem to a controllable process cause and corresponding corrective action.
Ishikawa Cause-and-Effect Diagram
Explore possible causes systematically, organise them into meaningful branches and distinguish hypotheses from causes confirmed by evidence.
Pareto Analysis
Rank loss categories, calculate cumulative contribution and focus improvement on the few categories that dominate the selected measure.
Histogram & Distribution Analysis
Visualise the distribution of measured data, compare it with specification limits and detect spread, skew, multimodality or unusual values.
Scatter Diagram & Correlation
Plot paired observations, estimate the strength and direction of association and reveal clusters, curvature or outliers that deserve investigation.
Control Chart & SPC
Plot process data in time order, calculate control limits and distinguish common-cause variation from signals that require investigation.
Poka-Yoke Error Proofing
Translate a specific error mechanism into prevention, detection or control concepts and evaluate them for reliability, response and new risk.
Process FMEA Risk Analysis
Connect process functions, failure modes, effects, causes and current controls, then prioritise prevention and detection improvements with accountable actions.
Muda Waste Analysis
Observe work, classify evidence across the eight wastes, estimate impact and convert the largest controllable losses into experiments or actions.
Process, Flow & Capacity
Process Flowchart
Build a clear sequence of activities, decisions, hand-offs and loops so the actual process can be discussed, checked and improved.
Process Mapping
Document activities with owners, inputs, outputs, time and value contribution to expose unclear responsibilities, delays and non-value-added work.
Value Stream Mapping (VSM)
Combine material flow, information flow, inventory, process data and timeline to understand end-to-end lead time and design a realistic future state.
Spaghetti Diagram
Trace real movement on a scaled layout, measure distance and frequency, and compare current and proposed routes before changing the workplace.
SIPOC Process Definition
Define suppliers, inputs, high-level process, outputs and customers to align scope and requirements before detailed mapping or problem solving.
Yamazumi Workload Chart
Stack work elements by station or operator, compare workload with takt time and identify overload, waiting and opportunities to rebalance work.
Production Line Balancing
Assign work elements to stations under takt, precedence and capability constraints, then compare efficiency, idle time and bottleneck risk.
Capacity & Production Balancer
Model daily and annual capacity, define fixed and variable capabilities, prioritise limiting factors and allocate compatible jobs to workplaces.
SMED Changeover Analysis
Record changeover activities, classify internal and external work, expose parallel opportunities and build a safer reduced-time standard.
Takt Time Calculator
Convert customer demand and net available production time into the required completion rhythm, then compare takt with cycle time and capacity.
Standard Work
Define the safest current best-known sequence, expected timing, standard inventory and key quality points so work can be trained, observed and improved.
Kanban Pull-System Sizing
Size a pull loop from demand, replenishment time, container quantity and justified safety factor, then define the signal and operating rules.
Just-in-Time Flow Assessment
Assess whether flow, takt, pull, levelling, quality and replenishment stability are ready to support lower inventory without increasing delivery risk.
Daily Management & Maintenance
OEE – Overall Equipment Effectiveness
Calculate Availability, Performance and Quality from transparent production data and trace the OEE gap to concrete loss categories.
Gemba Walk
Plan a respectful process-focused observation, capture facts and questions, recognise abnormalities and assign follow-up without turning the walk into an audit theatre.
Total Productive Maintenance (TPM)
Structure equipment losses, operator care, inspection standards, planned maintenance and improvement actions around the conditions required for reliable production.
Andon Response Design
Design call categories, triggers, ownership, target response, escalation and closure evidence so abnormalities receive visible and timely support.
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