5S audit, value stream, SMED, kaizen, and waste calculators. Browse our free lean tools below — all calculators are instant, accurate, and require no sign-up.
5S Audit Score Calculator — Calculate your 5S audit score from Sort, Set in Order, Shine, Standardize, and Sustain ratings. Assess workplace organization and lean maturity.
Andon Response Time Calculator — Calculate average andon response time from signal to resolution. Track escalation effectiveness and reduce production line stoppages.
A3 Problem Solving Savings Calculator — Calculate savings from A3 problem solving projects. Track the financial return of root cause analysis and countermeasure implementation.
Manufacturing Cell Design Calculator — Calculate the number of operators needed for a manufacturing cell based on work content and takt time. Design balanced production cells for lean flow.
Continuous Improvement ROI Calculator — Calculate the return on investment for your continuous improvement program. Compare annual cumulative savings against CI program costs and resources.
Gemba Walk Effectiveness Calculator — Calculate gemba walk effectiveness from issues identified, resolved, and impact value. Track leadership engagement and improvement outcomes on the shop floor.
Eight Wastes (DOWNTIME) Calculator — Calculate the total cost of the eight wastes of lean manufacturing: Defects, Overproduction, Waiting, Talent, Transport, Inventory, Motion, and Processing.
Kaizen Event ROI Calculator — Calculate the return on investment from kaizen events. Compare annual savings from process improvements against event costs and implementation expenses.
Hoshin Kanri Alignment Calculator — Calculate your hoshin kanri strategy alignment score. Measure how well your organizational objectives cascade and align from top-level goals to shop floor actions.
Kaizen Savings Calculator — Calculate savings from kaizen improvement events by comparing before and after costs, volumes, and implementation expenses. Quantify continuous improvement ROI.
Kanban System Design Calculator — Calculate the number of kanban cards and container size needed for a pull system. Design your kanban loop based on demand, lead time, and safety stock.
Line Balancing Efficiency Calculator — Calculate line balancing efficiency by comparing total task time to the product of stations and bottleneck cycle time. Optimize production line design.
Non-Value-Added Time Calculator — Calculate non-value-added time by subtracting value-added processing time from total lead time. Quantify waste in your manufacturing process.
Poka-Yoke ROI Calculator — Calculate the return on investment for poka-yoke (mistake-proofing) devices. Compare defect prevention savings against implementation costs.
Quick Changeover Calculator — Calculate changeover time reduction from current to target and the production capacity gained. Plan SMED and quick changeover improvement events.
SMED Savings Calculator — Calculate savings from SMED (Single-Minute Exchange of Die) setup reduction projects. Quantify freed capacity and cost savings from faster changeovers.
SMED Calculator (Single-Minute Exchange of Die) — Calculate SMED improvement by separating internal and external setup time. Reduce changeover time and increase manufacturing flexibility and capacity.
Takt Time vs Cycle Time Calculator — Compare takt time and cycle time to identify capacity gaps. Calculate how many units you can produce vs demand and where bottlenecks exist.
Value-Added Ratio Calculator — Calculate the value-added ratio by comparing value-adding process steps to total process steps. Identify non-value-added activities in manufacturing.
Value Stream Map Savings Calculator — Calculate potential savings from value stream mapping by comparing current state lead time costs to future state targets. Quantify VSM improvement value.
VSM Lead Time Ratio Calculator — Calculate the value stream mapping lead time ratio comparing value-added time to total lead time. Identify waste in your manufacturing process flow.