Lean Six Sigma Free downloads

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Lean Six Sigma Free Downloads

Search and download world-class Lean Six Sigma eLearning modules, tools, templates and other resources available for free, built for business problem solving. Sign-up to access all content for free.

5 Why Analysis Explained

The primary goal of the 5 Why technique is to determine the Root Cause of a defect or problem. This Worked Example provides an explanation for how to use this technique.

Day in Life of DILO Studies

Use this spreadsheets to Calculate and Graphically display the amount of Non Value Add activities in the process. Edit catogories and Customize according to your specific needs.

Scatter Plots

This is a simple spreadsheet regression analysis. Enter the Input variable (X) and output variable (Y) data that you want to plot to see if a change in the X value correlates in some way to a change in the Y.

Brainstorm Potential Root Causes

This template can be used to Identify and List the Sources of Variation relating to a specific problem.

Cause and Effect Analysis and Corrective Action Plan

Create a Fishbone Diagram and Enter Frequency of Failure by Cause to display Pie Chart breakdown by Group. Includes Corrective Action Plan (CAP) template.

QFD for Product Development

Create a QFD Step by Step by entering values in this spreadsheet to determine what you need to accomplish to satisfy or even delight your customers.

Changing Organisational Systems and Structures

Use these various Organisational Readiness Assesment techniques to understand the More of / Less of Behaviours required to reinforce the required changes and new practices.

FMEA Rating Scale

FMEA Scales for Severity, Occurrence & Detection to use in the Risk Scoring Matrix. Facilitates a more quantitative assessment and results.

Control Plan

Use this Control Plan Template to ensure that performance improvements made by the project team are sustained over time.

FMEA Poster Size Template

Welcome to the FMEA Poster Size Worksheet. This spreadsheet can be used to Identify potential Failure Modes and their Impact on process performance or product reliability.

Gauge Control Plan

Template to Assess the Stability, Linearity, Resolution, Bias and Precision of your measurement system. Use this template to track and control Measurement Error over time.

Preventative Maintenance Plan

This Preventative Maintenance Plan template can be applied to a process or an item of equipment to ensure it is operating correctly and to therefore avoid any unscheduled breakdown and downtime.

Success Sheet

Use this powerpoint template to summarize the "Before" and "After" picture and the project results achieved.

5W1H The Kipling Method Explained

The primary goal of the 5 W1H technique is to Define the Problem Statement. This reference guide provides an explanation of how to use this technique.

Cost of Poor Quality Guide

Checklist to evaluate Potential Areas for Cost of Poor Quality Savings, by Business Function.

DMAIC Roadmap

Watch this eLearning module to understand the most common approach used in Six Sigma DMAIC, key deliverables for each phase.

DMAIC Roadmap Poster

Infographic explaining key steps and deliverables to undertake during a Lean Six Sigma project.

From Mass Production to Lean

Explanation of major academic and practical study which was initiated with MIT as a partner to learn from the Japanese automobile industry, and especially from Toyota.

Lean Six Sigma Project Criteria

Example rating criteria used for DMAIC project certification. For each project, the phases of DMAIC are assessed using the anchored scale outlined. Examples are given to ensure consistency across the rating.

Process Variation Explained

To understand Six Sigma means that you first have to understand the principle of Process Variation as explained by this eLearning module.

Project Nightmare Infographic

Ignore the Voice of Customer at your peril, as illustrated by this Infographic.

What is Lean?

Understand fundamental Lean principles as practiced by Taichi Ono, originator of the Toyota Production System which we know today as the Lean philosophy.

What is Lean Six Sigma?

The Lean Six Sigma methodology is a merger of two distinct but complementary methodologies – Lean and Six Sigma. It enables a business leader to confidently solve process problems using data-driven appraoches so that the problems stay solved.

What is Six Sigma?

Six Sigma is a compilation of statistical concepts and other tools and techniques put together in a systematic way to get results, as explained by this eLearning video.

Project Charter

Create a Project Charter using this template to Define the Problem. Questions and Prompts in this template will guide you towards successful project chartering.


Some notes on developing a SIPOC process map including a couple of template examples to use on projects.

Design of Experimentation DOE

Use this DOE template in excel to conduct a 2^2 and 2^3 Factorial Design with upto 5 replicates and generate Main Effect and Interaction Effect Graphs.

Basic Lean Techniques- 5S, A3, 5 Why and Morning Mettings

Quick and simple explanation of Basic Lean Tools and Techniques and how this can be applied in any type of industry.

Decision Quality can be Evaluated by Six Factors

Decision Quality can be Evaluated by Six Factors as represented by this Spider Chart. Use this guide to evaluate the quality of any business decision.

Elevator Pitch

This is a simple, yet excellent communication tool to help the team link the Need for Change with the Vision of the Future. Essential for rallying the support and commitment of key project stakeholders.

Eliminating Waste

Explained: Eliminating waste is one of the most central themes in the Lean philosophy. Everything that cannot be characterized as directly value-adding for the end-user customer is to be regarded as waste.

More Of Less Of Chart

This tool is typically combined with the "bulls-eye" chart in an attempt to describe the future state at the behavioral level. It generally follows the drafting of a statement of project scope and a team mission.

Solution Evaluation Form

Simple template to assess all possible solution alternatives considered as part of process management. Includes estimated cost / benefit impact of each.

Calculate Process Capaability and Create Control Charts in Excel

Create P Control Chart for Discrete/Attribute Data and XBAR-R Control Chart for Continuous Data in Excel. Includes Cp, Cpk Process Capability analysis.

Sample Size Calculator

Use this to Decision Tree to calculate the Statistically Significant Sample Size for Continuous or Discrete Data, based on a certain level of confidence and precision.

Sigma DPMO Yield Calculator

Process Yield, Quality Levels, DPMO, Cpk and other Defect metrics (with or without the 1.5 sigma shift), includes conversion tables.

DPMO Sigma Cpk Conversion Chart

Use this conversion table to calculate corresponding DPMO, Sigma and Cpk values.

Z Table

Calculate the probability of an event occuring based on the Z value.

Data Collection Plan

This simple template outlines key parameters required as part of successful data collection planning. Populate the required fields based on your requirements.

Pareto Chart Template

Input data to Create a Pareto Chart in Excel. Edit catogories and Customize according to your specific needs.