Free Lean Six Sigma Excel Templates
Standardize your work and accelerate your projects with our curated collection of industry-proven templates. Download essentials for DMAIC, Kaizen, and 5S.
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PROFESSIONAL TOOLKIT
X-BAR CONTROL CHART
#
X1
X2
X3
Stat
1
10.5
10.4
10.6
PASS
2
10.2
10.3
10.3
PASS
3
9.8
9.7
9.9
FAIL
4
10.5
10.6
10.4
PASS
PROJECT CHARTER
BUSINESS CASE
PROBLEM STATEMENT
TEAM
MILESTONES
DMAIC: Define PPTX, XLSX
Project Charter
Formally authorizes a project, outlining its objectives, scope, stakeholders, and high-level plan for alignment.
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DMAIC REPORT
D
Define
M
Measure
A
Analyze
I
Improve
C
Control
DMAIC: All XLSX
DMAIC Project Report
Summarizes findings and outcomes from each DMAIC phase for clear communication and stakeholder review.
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PROBLEM
Manpower
Method
Machine
Material
Measurement
Mother Nature
DMAIC: Analyze XLSX
Fishbone Diagram
Visually brainstorm and categorize potential root causes of a problem to identify areas for investigation.
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FMEA: RISK ANALYSIS
FAILURE MODE
S
O
D
RPN
ACTION
2
4
3
24
9
8
5
360
6
3
7
126
DMAIC: Improve XLSX
FMEA Template
Proactively identify and mitigate potential failures in a process by analyzing their severity, occurrence, and detection.
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Strategy XLSX
Gantt Chart
Visually track project schedules, dependencies, and progress, ensuring tasks are completed in the correct sequence.
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MONITORING & RESPONSE PLAN
DMAIC: Control XLSX
Monitoring & Response Plan
Defines key metrics and establishes clear action plans for responding to deviations, ensuring process stability.
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DMAIC: Control XLSX
Control Plan
Documents the methods and metrics needed to maintain process improvements and prevent regression to the old state.
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RISK ASSESSMENT MATRIX
Impact →
Likelihood →
Strategy XLSX
Risk Matrix Template
Assesses and prioritizes risks based on their likelihood and impact, helping teams focus on critical threats.
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Strategy XLSX
Risk Assessment Form
Systematically identify, analyze, and evaluate potential risks within a project to inform mitigation strategies effectively.
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One Point Lesson
Topic: Proper Bolt Tightening
BEFORE (Incorrect)
Bolt is loose and at an angle.
AFTER (Correct)
Bolt is tight and perpendicular.
Lean Tools XLSX
One-Point Lesson
A simple, visual tool for quickly communicating a single key concept or standard procedure at the workplace.
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PICK Chart: Prioritization Matrix
High Payoff
Low Payoff
Low Effort
High Effort
Implement
Challenge
Possible
Kill
Lean Tools XLSX
PICK Chart
Categorize ideas based on payoff and difficulty to help teams prioritize which improvement actions to pursue first.
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Impact & Effort Matrix
High Impact
Low Impact
Low Effort
High Effort
Quick Wins
Major Projects
Fill-ins
Thankless Tasks
Strategy XLSX
Impact-Effort Matrix
Prioritize tasks by mapping their potential impact against the effort required, identifying quick wins and projects.
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Kaizen Newspaper
Dept: Assembly | Line: 04
Legend:
Date
Problem / Countermeasure
Owner
Status
10/24
Tool spacing Shadow board installed
J. Doe
10/26
Oil leaks on FL2 Seals ordered, pending
M. Smith
10/28
Labeling unclear Design drafted
K. Lee
11/01
Bin overflow Root cause analysis
R. Roy
Lean Tools XLSX
Kaizen Newspaper (PDCA)
A structured report for documenting a continuous improvement event using the Plan-Do-Check-Act cycle.
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OEE Calculator
Availability
Performance
Quality
Overall OEE
Lean Tools XLSX
OEE Calculator
Measures manufacturing productivity by combining availability, performance, and quality into a single key performance indicator.
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SIPOC DIAGRAM
S
Suppliers
I
Inputs
P
Process
O
Outputs
C
Customers
DMAIC: Define XLSX
SIPOC Diagram
Provides a high-level overview of a process, mapping Suppliers, Inputs, Process, Outputs, and Customers.
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Lean Tools XLSX
Value Stream Map
Visualize and analyze the flow of materials and information required to bring a product to a customer.
Coming Soon
5S AUDIT CHECKLIST
SortPASS
Set in OrderPASS
ShinePASS
StandardizePASS
SustainPASS
OVERALL SCORE95%
Lean Tools XLSX
5S Audit Checklist
Assess workplace organization and efficiency by evaluating Sort, Set in Order, Shine, Standardize, and Sustain.
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DMAIC: Measure XLSX
Data Collection Plan
Structures the process of gathering data, defining what to measure, how to measure it, and who is responsible.
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Balanced Scorecard
Financial
Revenue & ROI
Customer
Satisfaction
Internal
Process Eff.
Learning
Growth
Strategy XLSX
Balance Scorecard Template
Aligns business activities to the vision and strategy of the organization, improving communications and monitoring performance.
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5S RED TAGGING (SORT PHASE)
RED TAG
ITEM ID: GEARBOX-X9
REASON: OBSOLETE / BROKEN
DATE: 2023-10-27
ACTION: SCRAP / REMOVE
Lean Tools XLSX
5S Red Tag Template
A tool used in the 'Sort' phase of 5S to identify and manage items that are unnecessary in a work area.
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LESSONS LEARNED REPORT
What went well?
What went wrong?
Recommendations
Daily stand-ups for sync.
Version control for docs.
Early testing phases.
Strategy XLSX
Lessons Learned Template
Documents knowledge gained during a project so that it can be used to improve future project performance.
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Lean Tools XLSX
5S Audit Trend Template
Tracks and visualizes 5S audit scores over time to identify trends and measure the sustainability of improvements.
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5S TREND & ACTION PLAN
ACTION PLAN: (Due to Feb Dip)
Retrain team on 'Shine' standards.
Lean Tools XLSX
5S Audit Trend & Action Plan Template
Combines trend analysis of 5S audits with a structured action plan to address areas needing improvement.
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A3 PROBLEM SOLVING
1. Background
5. Countermeasures
2. Current State
6. Check
3. Goal
7. Follow-up
4. Analysis
COMPLETE
Lean Tools XLSX
A3 Problem Solving Template
A structured problem-solving tool that captures the entire improvement process on a single A3-sized paper.
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STANDARD WORK INSTRUCTION
Step 1: Prepare materials
Step 2: Assemble part A to B
Step 3: Inspect for defects
Lean Tools DOCX, XLSX
Standard Work Template
Documents the most efficient and reliable method for performing a task, ensuring consistency and quality.
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DMAIC: Measure XLSX
Process Flow Diagram Template
Visually map out the steps, decisions, and flow of a process to understand, analyze, and improve it.
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PROJECT ACTION LIST
Task
Progress
Status
...
...
Strategy XLSX
Action List Template
Tracks tasks, owners, and due dates to ensure project activities are systematically completed on time.
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5 WHYS: ROOT CAUSE ANALYSIS
Problem Statement
↓
Why? → ...
↓
Why? → ...
↓
Root Cause
DMAIC: Analyze XLSX
5 Whys Template
A root cause analysis technique to explore the cause-and-effect relationships underlying a particular problem.
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SWOT ANALYSIS
Strengths
Weaknesses
Opportunities
Threats
Strategy XLSX
SWOT Analysis Template
A strategic planning tool to identify Strengths, Weaknesses, Opportunities, and Threats related to business competition or project planning.
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TERMINOLOGY REFERENCE
Aa
Andon Noun
Gemba Noun
Kaizen Noun
Muda Noun
Lean Tools PDF
Lean & CI Terminology Sheet
A comprehensive glossary defining key terms, acronyms, and Japanese words used in Lean and Six Sigma.
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8D Problem Solving Process
D1
D2
D3
D4
D5
D6
D7
D8
Lean Tools XLSX
8D Problem Solving Template
A structured eight-discipline approach to problem-solving, commonly used by quality engineers or other professionals.
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Is / Is Not Analysis
IS
IS NOT
What
Where
When
Who
How
DMAIC: Define XLSX
Is/Is Not Analysis Template
A problem-scoping tool that clarifies boundaries by examining what the problem is, and what it is not (Who, What, Where, When, How).
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Project Criteria Matrix
Project
Cost
Impact
Score
Project Alpha
8
9
8.5
Project Beta
6
7
6.5
Alpha
Beta
Strategy XLSX
Project Criteria Matrix Template
A decision-making tool used to evaluate and prioritize a list of options against a set of weighted criteria.
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RACI MATRIX
TASK
PM
DEV
QA
Define Scope
A
R
C
Create UI
C
A
I
User Testing
I
R
A
Strategy XLSX
RACI Matrix Template
Defines roles and responsibilities for project tasks to ensure clarity and accountability.
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RAID LOG
Risks
Assumptions
Issues
Dependencies
Strategy XLSX
RAID Log Template
Tracks Risks, Assumptions, Issues, and Dependencies to proactively manage project uncertainties.
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Strategy XLSX
Communication Plan Template
Outlines how project information will be communicated to stakeholders, including what, when, and how.
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Stakeholder Analysis
High Power
Low Power
Low Interest
High Interest
Keep Satisfied
Manage Closely
Monitor
Keep Informed
Strategy XLSX
Stakeholder Analysis Template
Identifies key stakeholders and maps their influence and interest to develop engagement strategies.
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DMAIC: Analyze XLSX
Scatter Plot Template
Investigate relationships between two continuous variables to identify potential correlations.
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DMAIC: Measure XLSX
Histogram Template
Visualize the frequency distribution of a dataset to understand its shape, center, and spread.
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DMAIC: Analyze XLSX
Pareto (80/20) Template
Identifies the vital few causes from the trivial many, helping prioritize efforts on factors with the greatest impact.
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8 WASTES (DOWNTIME)
Defects
Overproduction
Waiting
Non-Utilized Talent
Transportation
Inventory
Motion
Extra Processing
Lean Tools DOCX
Waste Walk Template
A structured checklist for observing a process at the Gemba to identify the 8 wastes of Lean.
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VALUE ANALYSIS
Before
After
Non-Value Add
Value Add
Lean Tools XLSX
Value Analysis Template
Systematically analyze and improve the value of products or processes by examining function and cost.
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Lean Six Sigma Templates & Tools
Accelerate your continuous improvement projects with our comprehensive library of Lean Six Sigma templates. Whether you are leading a DMAIC project, conducting a Kaizen event, or implementing 5S in the workplace, our collection provides the essential tools you need to succeed. Browse and download professionally designed resources including Project Charters, Fishbone Diagrams, Value Stream Maps, and Control Plans. Available in high-quality Excel, PowerPoint, and PDF formats, these templates are designed to help you analyze data, identify root causes, and drive operational excellence.