1. LEAN IMPLEMENTATION Training SUMMARY OF RESULTS
DATE :_________________
SHORT TERM F/U DATE:_______________
LONG TERM F/U DATE:________________
This form is used to measure the impact of the Training changes (implemented and forecasted/planned). Reference the measurement handout for definitions, calculations.
The section on the bottom, “additional savings identified” is intended to capture other Training impacts that can be quantified in dollars. Two subject areas are shown: 1) resource conservation and pollution prevention - to cover impacts in this focused area and 2) other: investment, specifications, transportation, etc. - To cover impacts in all other areas some of which are suggested here. Information to be provided is the number of items in each subject area, each item should equate to a dollar impact, date updated is used during follow-up, $ potential is the estimated savings impact, $ approved is the savings approved after investigation, and $ rejected is the savings amount rejected after investigation.

2. Observation Worksheet: Identification of Waste
Key Point
Observations
Overproduction
(Too much / too fast)
Correction
(Rework & inspect)
Material Movement
(Too much / too far)
Processing
(Adds no value)
Use this form for the identification of waste worksite exercise. Team members should note what they observe and what might be changed to improve the situation.
Inventory
(Excess stock, banks)
Waiting
(Idle time)
Motion
(Inefficient movement)
Unevenness
Overburden
Current Methods

3. Observation Worksheet: Identification of Waste
Key Point
Resource Conservation and Pollution Prevention
Energy
(Excess usage)
Water
(Excess usage)
Transportation
(Fuel use / emissions)
Hazardous Waste
(Toxicity / cost)
This form can be used during the Training to identify specific items relating to resource conservation and pollution prevention.
It may be beneficial to create a two sided form with this on one side and the previous identification of waste form on the other.
Non-Hazardous
Waste
(Inefficiency / cost)
Product Design
(Cost / ineficiency / toxicity)
Environmental
Management
Practices
(Excess usage / waste)
Other

4. Observation Worksheet: Workplace Organization & Visual Control
Key Point
Observations
Visual Control
(Status at a glance)
Audio Control
(Understandable)
Workplace Organization
(Everything in its place)
Boundary Samples
(Good vs. bad)
Process Control
Manual & Automatic
(Bad parts not passed on)
Use this form for the workplace organization and visual control worksite exercise. Team members should note what they observe and what might be changed to improve the situation.
Facilities / Equipment
(Layout 'U' cells)
Flexible System
(Quick setup & change capability)
Decoupled Process
(Stop part but not all of line)
Knowledge By
Walking Around

5. Observation Worksheet: Pull System
Key Point
Observations
Pull Systems
(Replenishment based on
consumption)
Pull Signals
(Type used & why)
Inventory Levels
(Stock, WIP, banks)
Stock Dates
(FIFO vs. FISH)
Distance Traveled
(Part, WIP,conveyor lengths)
Use this form for the pull worksite exercise. Team members should note what they observe and what might be changed to improve the situation.
Small Lot Production
(Minimum material quantity
and flow)
Containerization
(Quality part presented to
operator)
Supplier Involvement
(External of process or
obvious boundary)
Leveling
(Smooth flow vs. too much / little
work, equipment, facilities, people)

6. Standardized Operations Worksheet and Layout
STEP
NO.
WORKSTATION AREA DRAWN TO SCALE
OPERATION:
FROM:________________________
QUANTITY PER SHIFT:______________
CUSTOMER CYCLE TIME:__________________
TO: __________________________
SHIFT:________
OPERATOR CYCLE TIME:__________________
WORK ELEMENT
ELEMENT TIME
STANDARD IN-
QUALITY
CRITICAL
HAND WORK
MACHINE
WALK
PROCESS STOCK
CHECK
OPERATION
SAFETY C Q
TOTAL
Use this form for the standard operation worksite exercise. Team members should note what they observe as the process steps, the layout, process flow and other information regarding the worksite.
Worksheet and layout instructions:
1. Fill in header information.
2. Draw in equipment and material locations.
3. Observe operation and enter task sequence and times. Walk
times occur between tasks, and should be listed as separate
steps.
4. Number position of each task in layout.
5. Contact each numbered task to show walking path of the
operator.

7. This form is used to capture the action plan items the Training team identifies as needing to be accomplished following the Training to implement various improvements. It is important that timing and responsibilities be specifically identified.

8. Lean Implementation Training Process Flow
Select
team
members
Make all people
affected aware
of what is
going to happen
Identify
pilot
area
Define
current
situation
Identify
opportunities
to improve
Look for new
opportunities
Lean Implementation Training Process Flow
Recognize
efforts of
people
This graphic represents the Training process that is followed for a Lean Implementation Training. It basically follows a continuous improvement methodology with an additional emphasis on aggressive implementation.
Analyze
& select
Discuss plan
with
stakeholders
Verify
& adjust
Implement
new method
A.S.A.P.
Develop
new method
(apply zero/low
cost ideas first)
OPERATION:
FROM:___________________________
QUANTITY PER SHIFT:______________
CUSTOMER CYCLE TIME:__________________
TO: _____________________________
SHIFT:________
OPERATOR CYCLE TIME:__________________
DESCRIPTION OF
ELEMENT TIME
STANDARD IN-
QUALITY
CRITICAL
NO.
OPERATION
HAND WORK
MACHINE
WALK
PROCESS STOCK
CHECK
SAFETY
WORKSTATION AREA DRAWN TO SCALE C Q
03/23/94

9. Process Flow Chart and Data Worksheet
Process / Product Description: ____________________________________ Page ____ of ____ S t e p #
Process
Step
Description o r M v I n s c P
Time
for the
per
unit
Distance
Traveled
feet
miles
______
Other
Manufg.
Costs
Material
Cost
Freight or
Packaging
Quantity in
Storage
Buffer 
Date completed: ______________ Prepared by: ______________________ Co. Name: ______________________
Comments
This form is used in pre-Training activity and sometimes in the early data gathering stage of a Training. Its purpose is to collect relevant
work site information to assist the team in understanding where time, cost exists.

10. PROCESS STEP DESCRIPTION
Lead Time Analysis
Process / Product Description: ____________________________________ Page ____ of ____ S T E P # T I M E D I S T. Q T Y. V A N V A
PROCESS STEP DESCRIPTION
This form is used to assist the team in determining lead time for a process or activity.
Date completed: ______________ Prepared by: ______________________

11. VALUE ADDED TIME + NON-VALUE ADDED TIME
x 100
VALUE ADDED TIME
VALUE ADDED TIME + NON-VALUE ADDED TIME
This is the lead time analysis graphic tool worksheet and is used to identify the value added and non-value added lead time of the sequential process steps for a given activity, process, procedure. The percentage of value added work should be calculated when the process steps are all listed and timed.

12. Training Checklist

13. Training Checklist