Lean & OpEx guides
Operational excellence guides
32 guides for plant, operations and quality leaders. Each one gives you the agenda, the board layout, the worked example and the failure modes, not the theory. Find the method you need below.
Strategy deployment
Turning annual objectives into commitments, KPIs and reviews that stick.
Hoshin Kanri
The seven-step annual cycle, a worked cascade to department KPIs and the review rhythm.
X-Matrix
How to read one counterclockwise, fill it in one afternoon and keep it alive.
Catchball
How targets become commitments through data-carrying rounds between levels.
KPI Tree
Build a three-level tree from one business result down to shift-owned metrics.
Management Review
A 90-minute exception-based agenda and a decision log that keeps red numbers honest.
Obeya
The four-wall layout, a weekly 60-minute review agenda and physical vs digital compared.
Daily management
Boards, meetings, routines and standards that catch deviations the same day.
Lean Daily Management
Boards, tier meetings, escalation and leader standard work as one loop, with a 90-day plan.
SQDIP Boards
What each letter tracks, red/green rules, the 10-minute board meeting and a board layout.
Tier Meetings
A three-tier structure with agendas, escalation rules and response times.
Leader Standard Work
Routine cards for supervisor, area manager and plant manager, with time budgets.
Gemba Walk
A question bank, a walk structure card and a cadence by leadership level.
Standardized Work
The three elements, a worked assembly-cell example and standards that live.
5S
What each S produces, a week-by-week pilot rollout and the audits that keep it alive.
Layered Process Audits
A three-layer structure with time budgets and question design rules that find real problems.
Problem solving and quality
From a red on the board to a root cause that stays fixed.
5 Whys
The rules that keep a chain honest, a good vs bad worked chain and when to move up to A3.
A3 Problem Solving
The eight sections with a coaching question for each and a filled example A3.
RCCA
A seven-stage flow with exit criteria, containment vs corrective vs preventive action.
8D Report
All nine disciplines D0 to D8, escape point analysis and an approver's checklist.
FMEA
A worked PFMEA extract with consistent S, O and D scores and the triggers that keep it alive.
Poka-Yoke
The four device mechanisms, the effectiveness hierarchy and a worked torque-station example.
Flow, losses and performance
Seeing the value stream, measuring the losses and taking them out.
Value Stream Mapping
Key metrics, a mapping-week agenda and a worked current-to-future state example.
Future-State VSM
The seven flow questions, a worked example with supermarkets and a pacemaker.
7 Wastes of Lean
DOTWIMP with plant-floor examples and a 10-prompt waste-spotting walk sheet.
Manufacturing KPIs
Definitions and formulas for 17 core KPIs grouped by SQDIP, plus selection rules.
OEE
A stepwise worked calculation, the six big losses and the ways OEE misleads.
SMED
The four-stage method and a worked 47-to-18-minute changeover breakdown.
TPM
The five steps of autonomous maintenance and the operator/maintenance responsibility split.
World Class Manufacturing
What WCM is, its ten technical and ten managerial pillars, and how it relates to Lean.
Improvement and people
A kaizen system that keeps producing, and the capability to run it.
Kaizen
An idea pipeline from capture to verified benefit, three lanes and honest health metrics.
Kaizen Events
A two-week preparation checklist, a five-day agenda and the 30-day follow-up list.
Yokoten
A six-step transfer checklist and how to make lateral deployment systematic across plants.
Skills Matrix
A four-level qualification scale, a worked six-operator example and coverage rules.
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