The Industrial Engineer's Toolkit

Model. Simulate.
Optimize.
All your IE tools in one place.

SymplProcess is the all-in-one platform built for industrial engineers. Flow Modeler for multi-stream process mapping. Mixed Shop Modeler for mixed-model simulation. 15+ pro engineering tools, training tracks, and ready-to-use templates.

Open Flow Modeler → Explore All Tools
2 Modelers
Flow + Mixed Shop simulation
15+
Pro engineering analysis tools
300+
Guides, tracks & training content
14
Free IE calculators
⚙️
Flow Modeler
Multi-Stream Process Mapping
Critical path analysis, bottleneck detection, staffing optimization with Theory of Constraints, and Monte Carlo simulation.
→
🏭
Mixed Shop Modeler
Mixed-Model Production Simulation
Factory floor visualization, routing diagrams, output scheduling, and multi-product simulation for mixed-model environments.
→
🛠️
Pro Tools & Learning
15+ Engineering Analysis Tools
OEE, line balancing, SMED, WIP analysis, cost modeling, capacity planning — plus 300+ training guides and ready-to-use templates.
→
The Problem
Your engineering analysis is scattered across
spreadsheets, Visio, and tribal knowledge.
📐
Process models live in static diagrams
Visio and PowerPoint don't calculate throughput, find bottlenecks, or run simulations. You spend hours building models that can't answer "what if?"
🔢
Staffing is guesswork
You assign headcount based on gut feel, not cycle times and constraints. Some processes are overstaffed while your bottleneck starves — and nobody sees it until output drops.
🧮
Every analysis needs a new spreadsheet
OEE, line balancing, cost-per-unit, capacity planning — each one is a separate Excel file. No tool connects your process flow data to the analysis that matters.
💰
Enterprise tools cost six figures
Arena, FlexSim, and PlantSimulation are powerful but expensive and complex. You need engineering-grade tools that work on day one without a consulting engagement.
What's Inside the Platform
Everything an industrial engineer needs — connected.
Model your processes once. Throughput calculations, staffing optimization, Monte Carlo simulation, and 15+ analysis tools all flow from that single source of truth. No modules to buy — every feature works together.
Receiving
7 staff · 500/hr
Picking
3 staff · 280/hr
Packing
4 staff · 400/hr
Flow Modeler
Flow Modeler:
Map → Analyze → Optimize
Define your entire production flow with multi-stream process maps and cross-stream dependencies. The system finds the critical path, calculates lead times, detects bottlenecks, and optimizes staffing using Theory of Constraints math.
  • Multi-stream process flows with cross-stream dependencies
  • Critical path, lead time, WIP, and pile-up calculations
  • Automatic bottleneck detection and constraint analysis
  • TOC staffing optimization — demand-based or throughput-based
  • Save and compare scenarios before committing to a plan
System Throughput Distribution 1,000 iterations
P10: 2,412 Mean: 2,847 P90: 3,294
Std Dev
342
Bottleneck
Picking
Risk
Low
New — Pro
Monte Carlo Simulation
Run 1,000+ iteration simulations on your process flow to model real-world variation. See the probability distribution of your throughput, identify which processes bottleneck most often, and quantify risk before it hits the floor.
  • Normal, lognormal, bimodal, triangular, and uniform distributions
  • Per-process bottleneck frequency and pile-up detection
  • P10/P50/P90 output ranges for every process and the full system
  • Risk assessment with actionable recommendations
Staffing Solver
Target: 500/shift
Receiving
60s cycle · 88% util
7
OPTIMAL
= 7
Picking
BOTTLENECK
4m cycle · 72% util
6
OPTIMAL
-2 ↓
Packing
2m cycle · 81% util
4
OPTIMAL
-1 ↓
CURRENT
28
OPTIMAL
24
SAVINGS
-4
New — Pro
Manpower Optimization
Set a throughput target and instantly see the optimal headcount for every process. Find where you're overstaffed, where you're short, and exactly how many people each step needs — backed by TOC math.
  • Automatic headcount solver with capacity buffer settings
  • Bottleneck identification and utilization analysis
  • Current vs optimal staffing delta with cost impact
  • Recommendations for understaffed and overstaffed processes
My People — Live
Week of Mar 3
R
Ryan Mitchell
Engineer
3/4
🔒 Locked
P
Priya Sharma
Engineer
2/5
✏ Draft
C
Carlos Martinez
Engineer
6/6
✅ Done
Live Activity
+ Ryan added: "Calibrate inspection fixtures" 2m ago
✓ Carlos completed: "Update P&ID drawings" 8m ago
− Priya removed: "Vendor call (rescheduled)" 15m ago
New — Pro
Engineering Task Tracker
Your entire engineering team's week at a glance. Managers see every task, every status, every change — live. Assign work, track progress, and catch blockers before they become problems. Engineers get a clean weekly planner. Managers get full visibility.
  • My Week: drag-and-drop weekly planner with inline quick-add
  • My People: live team dashboard with real-time activity feed
  • Assign tasks to any team member directly from the manager view
  • Plan lifecycle: draft → locked → review → completed
  • Track added, removed, and completed tasks with full changelog
  • Outlook sync — export .ics files for individuals or the full team
  • Inline team management — add, edit, remove members without leaving the page
New
Performance Trends
See production, safety, downtime, and quality trends over 7, 14, or 30 days. Daily or weekly view. Built-in conversation starters for every role — walk into any meeting with data.
  • Production planned vs actual with adherence %
  • Downtime stacked by category — show mechanics the data
  • Safety incidents and near-miss tracking
  • Quality yield trend with auto-generated talking points
Shift Report ● Live
Schedule
96%
Quality
98.2%
Avail
100%
Downtime
12m
Live Streaming
Shift Reports That Write Themselves
Production targets auto-populate from your staffing plan. Just fill in actuals as the shift runs. Safety, quality, downtime — everything in one form. Submit in under 3 minutes.
  • Production targets auto-populated from your staffing plan — zero manual entry
  • Live auto-save — manager sees progress before submission
  • Add or remove processes freely — full supervisor flexibility
  • Staffing context shows bottlenecks right in your report
42%
Jams
28%
Setup
15%
Material
10%
PPE
5%
Other
Analysis
Pareto & Root Cause
Automatically identify the vital few causes driving 80% of your defects and downtime. Filter by date, facility, product. Add manual entries to supplement shift data.
5S Audit Score
82%
8 pass · 2 fail · 0 skip
Audits
5S & Safety Audits
Walk-through zone-by-zone audits with custom checkpoints, photo uploads, issue tracking, and trend scoring. Create action items directly from findings.
🏭
Main Plant
12 supervisors · 3 shifts
📦
Distribution Center
8 supervisors · 2 shifts
🔧
Service Center
4 supervisors · 1 shift
Organization
Multi-Facility, Role-Based
One org, many sites. Google OAuth login means zero IT setup. Your entire engineering team can access the same process models, analysis tools, and learning content from any device.
More Than a Calculator
Map your entire operation. Find the critical path.
Maximize throughput with the same headcount.
This isn't a spreadsheet with formulas. Define your production streams, connect processes across streams, and let the system find what's limiting your throughput. It calculates lead times, identifies constraints, shows cross-stream dependencies, and tells you exactly where to put your people to maximize output.
Multi-Stream Process Map with Cross-Stream Dependencies
INBOUND OUTBOUND PRODUCTION 100% merge Receiving 5 staff · 600/hr · 0.4h QC Inspection 2 staff · 450/hr · 0.6h Putaway 3 staff · 520/hr · 0.3h FORK Picking 4 staff · 280/hr · 1.2h BOTTLENECK Packing 6 staff · 450/hr · 0.5h Shipping 3 staff · 500/hr MERGE Assembly 8 staff · 340/hr · 0.8h Testing 2 staff · 400/hr · 0.4h Labeling 1 staff · 600/hr · 0.2h CRITICAL PATH: Recv → QC → Put → Pick → Pack → Ship Critical path Cross-stream edge
⚠️
Critical Path: Receiving → QC → Putaway → Picking → Packing → Shipping
Picking at 280/hr is the constraint. Adding 2 people here increases system throughput by 140/hr.
3.2h
Critical Path Lead Time
1,420
WIP Units in System
280/hr
System Throughput (Constrained)
🔀
Multi-Stream with Cross-Stream Dependencies
Define inbound, outbound, production, and custom streams. Processes can feed across streams — Putaway feeds Picking, Labeling merges into Shipping. The system traces how material actually flows through your operation, not just within a single line.
🎯
Critical Path & Bottleneck Detection
The system automatically finds the longest path through your operation — the critical path that determines your total lead time. It identifies the constraint limiting system throughput, so you know exactly where to focus improvement efforts.
⏱️
Lead Time & WIP Calculations
Lead time calculated at every process and accumulated across the critical path. WIP and pile-up detection show where inventory backs up. You see not just where the bottleneck is, but the downstream impact on every other process.
🧮
Maximize Throughput with the Same People
Two optimization modes: Demand-Based allocation moves surplus staff to the bottleneck. Throughput Optimization equalizes capacity across all processes. Both show you the financial impact — dollars saved per shift, annualized.
📊
Scenarios, Quality & Variation Modeling
Model First Pass Yield per process, operator vs. process-driven variation, and multi-shift scheduling. Save and compare scenarios — "what if we add 2 people to Picking?" — before committing to a staffing plan.
Free — No Login Required
Try the Process Modeler right now
Map your production flow, find bottlenecks, and optimize staffing — all in your browser. Sign in later to save your work to the cloud.
Open Process Modeler →
Structured Weekly Planning
One weekly planner. Every task. Nothing missed.
Open your engineering workbench and see everything for your week — standard work, project tasks, improvement initiatives, and deadlines. Active tasks shift left so you always know what to focus on next.
Good morning, Alex
3 of 6 done
✓
Review shift handoff from 2nd shift
Done
✓
Resolve 2 open action items
Done
✓
Complete 5S audit — Zone B
82%
▶
Safety walk — loading dock area
In Progress
Walking checklist: PPE compliance, spill stations, emergency exits, forklift clearance zones. Add observations and photos as you go.
•
Gemba walk — packaging line
•
Submit shift report
Targets ready
Why It Matters
No more hunting through
three apps and a whiteboard.
📋
Shift-left active task
The current task visually shifts to the left and expands, so your eye is always drawn to what needs attention right now. Completed tasks fade back. Next tasks wait in line.
🔗
Auto-built from your processes
Tasks aren't manually entered — they're generated from your process definitions, Leader Standard Work configuration, open action items, and previous shift's handoff notes. Define it once, it shows up every day.
⚡
Targets pre-populated
Your shift report already has production targets from the process planner's staffing calculation. The supervisor just fills in actuals as the shift runs. Three minutes, start to submit.
Why Define Your Processes?
The model is the foundation. Everything else builds on it.
Most tools treat processes as a flat list. SymplProcess lets you model the actual flow — with dependencies, constraints, and capacity math. Once defined, that model powers your staffing, targets, reports, and trend analysis automatically.
01
Staffing becomes math, not gut feel
Your cycle times, availability, and headcount feed directly into TOC optimization. The system tells you where to put people — and shows you why.
02
Targets write themselves
Production targets in your shift report auto-populate from the process model. No more manually calculating what your team should produce. Change headcount, targets update.
03
Bottlenecks are visible, not hidden
When your model shows Picking at 280/hr constraining the whole system, the conversation shifts from "we need more people" to "we need people HERE." Data replaces politics.
04
New supervisors onboard in minutes
The process model IS the tribal knowledge. A new supervisor doesn't need to learn from a veteran over 6 months — they open the app and see every process, rate, and dependency.
05
Trends become meaningful
When you trend planned vs actual against a defined process model, you're not just charting numbers — you're comparing reality against a clear standard. Gaps have context.
06
Continuous improvement has a baseline
You can't improve what you haven't defined. Your process model is the "current state" of a value stream map — a living document that evolves as your operation gets better.
This is process modeling software that also runs your floor.
Most process tools stop at the diagram. SymplProcess connects the model directly to your daily operations — staffing, shift reports, audits, action items, and trends all flow from the same process definitions.
It's an operations platform built on a real process engine. Not a dashboard bolted onto a spreadsheet.
3
Streams per facility
∞
Processes per stream
3
Shifts with unique staffing
Open the Flow Modeler →
Built for Industrial Engineers
Two powerful modelers. One connected platform. Zero spreadsheets.
The Flow Modeler lets you map your entire operation — multi-stream, with cross-stream dependencies, cycle times, capacity math, and critical path analysis. The Mixed Shop Modeler handles mixed-model production environments with routing diagrams and factory floor simulation.
Think of it as Visio — but with real math behind it. Every node has cycle time, staffing, availability, yield, and variation built in. Change a number, and the entire model recalculates. Then run Monte Carlo simulation, what-if scenarios, and 15+ analysis tools.
📐
Current-State & Future-State Modeling
Model your operation as it is today. Save it. Then create a future-state scenario with different staffing, cycle times, or process changes. Compare throughput side by side.
🔬
Capacity Studies & Line Balancing
Run capacity analysis across your entire flow. See where you have excess capacity and where you're constrained. Test "what-if" headcount changes without touching the floor.
📊
Justify Headcount with Data
Show management exactly why you need 2 more people at Picking — not with a gut feel, but with a model that shows the constraint, the throughput gain, and the dollar impact per shift.
🏗️
New Line & Facility Planning
Designing a new production line or warehouse layout? Build the process model first. Validate throughput targets, staffing requirements, and lead times before breaking ground.
Open the Process Planner →
What You Can Model
✓
Multiple independent streams — inbound, outbound, production, custom
✓
Cross-stream dependencies — process A in Stream 1 feeds process B in Stream 2
✓
Cycle time, availability & performance — per process, per shift
✓
First Pass Yield & defect modeling — quality loss flows through the system
✓
Operator & process variation — min/max output range per process
✓
WIP, lead time & pile-up detection — where inventory accumulates
✓
Critical path identification — the longest chain determining total lead time
✓
Scenario save & compare — snapshot current model, try changes, compare results
SymplProcess vs. Traditional Tools
Visio / Lucidchart
Pretty diagrams, zero math
SymplProcess
Every node calculates throughput, lead time, WIP
Excel models
One-off, breaks when shared
SymplProcess
Persistent, shareable, scenario-based
Simulation software
$50K+ license, months to configure
SymplProcess
$9.99/mo, model in minutes
Your Engineering Toolkit
Three pillars. One connected platform.
Everything you need to model, analyze, and optimize — all in one place.
📐
Model
Flow Modeler + Mixed Shop Modeler
  • Multi-stream process flow mapping with cross-stream dependencies
  • Critical path, lead time, and bottleneck detection
  • Mixed-model production simulation with routing diagrams
  • TOC staffing optimization — demand or throughput based
  • Factory floor canvas and output schedule visualization
🔬
Analyze
15+ Pro Engineering Tools
  • Monte Carlo simulation with N-iteration probabilistic analysis
  • OEE tracking with Six Big Losses breakdown
  • Yamazumi line balancing, SMED changeover analysis
  • WIP & queueing analysis, capacity planning, cost modeling
  • What-if scenario comparison and manpower optimization
🎓
Learn
Training, Templates & Tools
  • 300+ guides on Lean, Six Sigma, TOC, and IE methods
  • 16 structured learning tracks with quizzes and certification
  • Interactive templates — A3, PDCA, Fishbone, FMEA, and more
  • 14 free IE calculators — OEE, takt time, cycle time, and more
  • AI Process Coach powered by Claude
Free Calculators
Manufacturing tools you can use right now — no sign-up required.
Instant, open-access calculators for OEE, takt time, cycle time, yield, downtime cost, and more. Bookmark them, share them, use them every day.
⚙️
OEE Calculator
Availability × Performance × Quality — the gold standard metric.
Calculate →
⏱️
Takt Time Calculator
Find the production pace needed to match customer demand.
Calculate →
🔄
Cycle Time Calculator
Measure how long one unit takes from start to finish.
Calculate →
✅
First Pass Yield
What percentage passes quality inspection the first time?
Calculate →
💰
Downtime Cost
The true cost of unplanned downtime per hour, shift, and year.
Calculate →
📊
DPMO & Sigma Level
Convert defect rates to DPMO and process sigma level.
Calculate →
📐
Line Efficiency
How balanced is your production line across all stations?
Calculate →
👷
Labor Productivity
Output per labor hour and cost per unit for your team.
Calculate →
View All 14 Free Calculators →
🎓 Built-in Training
Learn lean operations
while you work.
Interactive lessons for every role — supervisors, managers, and facility leaders. Learn the 8 wastes, 5S, shift reporting best practices, and production scheduling with quizzes that connect directly to the tools you use every day.
🎯
Role-based learning paths
Supervisor, Manager, and Facility Monitor tracks with lessons tailored to each role's daily work
🧠
Interactive quizzes & scenarios
Test your understanding with real-world scenarios and get immediate feedback
🔗
Connected to your tools
Every lesson links directly to the SymplProcess feature it teaches — learn, then do
Explore the Training Academy →
🏭
Foundation
Why SymplProcess Exists
The shift change problem, tribal knowledge loss, and the 5 lean principles that fix it.
3 lessons · 15 min
🗑️
Waste Elimination
The 8 Wastes (DOWNTIME)
Interactive cards for each waste type with real-world examples from the floor.
8 modules · 20 min
📋
Supervisor Track
Mastering Shift Reports
The S-Q-P-E-P framework for writing reports that drive action, not just record data.
5 lessons · 25 min
⚙️
Systems
Production Scheduling
Forward vs backward scheduling, ERP/MES integration, and where SymplProcess fits.
4 lessons · 20 min
Knowledge Hub
Learn lean manufacturing from the ground up.
Free guides covering the principles, tools, and frameworks behind operational excellence — written for people who work on the floor, not in a textbook.
🏭
Foundation
Lean Manufacturing
The 8 wastes, 5 principles, and how to start eliminating waste today.
📊
Quality
Six Sigma (DMAIC)
Reduce defects to 3.4 per million with the DMAIC methodology.
🔗
Throughput
Theory of Constraints
Find the bottleneck, exploit it, and lift the whole system.
🗺️
Analysis
Value Stream Mapping
See every step, every delay, every handoff — then redesign the flow.
🧹
Workplace
5S Methodology
Sort, Set in Order, Shine, Standardize, Sustain — visual workplace basics.
🔄
Culture
Kaizen
Small daily improvements that compound into transformational change.
🔀
Flow
Push vs Pull Systems
Why building to forecast fails and how pull systems fix it.
⚡
Strategy
Lean Six Sigma
Combine lean speed with Six Sigma precision for maximum impact.
Browse All Guides →
Pro Feature
107 Pro Knowledge Checks
Go beyond theory. Every lean and operations concept has a hands-on knowledge check — test your understanding, compare scenarios, export results, and build real expertise through guided practice.
📊
OEE Analysis Suite
Multi-machine OEE, six big losses, trend tracking, improvement priority
6 tabs · Knowledge Check →
🔗
Bottleneck & TOC
Process simulator, drum-buffer-rope, what-if analysis, throughput sensitivity
6 tabs · Knowledge Check →
📈
Statistical Process Control
X-bar/R charts, Western Electric rules, capability analysis, pattern detection
6 tabs · Knowledge Check →
⚠️
FMEA Builder
Full FMEA table, RPN calculator, risk matrix heatmap, action tracker
6 tabs · Knowledge Check →
🗺️
Value Stream Mapping
Current/future state builder, lead time ladder, information flow mapper
6 tabs · Knowledge Check →
🎲
Monte Carlo Simulation
Distribution modeling, N-iteration runs, confidence intervals, risk quantification
6 tabs · Knowledge Check →
📋
Kanban System
Pull system simulator, cumulative flow diagram, WIP optimizer, lead time analysis
6 tabs · Knowledge Check →
⚖️
Line Balancing
Yamazumi charts, operator assignment, takt time calculation, efficiency optimization
6 tabs · Knowledge Check →
✓ Save & resume your work
✓ Export to CSV
✓ Compare scenarios
✓ Auto-save as you work
Browse All 107 Knowledge Checks →
Simple Pricing
Free to start. Pro when you're ready.
Use the process modeler, all 14 calculators, 9 templates, 200+ guides, and the full learning library for free. Upgrade to save your work and unlock the complete operations platform.
Free
$0/forever
Learn and explore. No credit card needed.
  • 📖 Learning & Resources
  • 200+ lean & manufacturing guides
  • 5 operations frameworks
  • 80+ term glossary
  • 14 free calculators (OEE, takt, yield, etc.)
  • 9 templates with PDF/CSV export
  • 🏭 App Access
  • Process modeler (no login required)
  • 1 facility, up to 3 processes
  • Basic shift reports (7-day history)
  • Training Academy (browse all lessons)
Get Started Free
Most Popular
Pro
$9.99/mo
The full platform. Save everything. Up to 5 members.
  • Everything in Free, plus:
  • 🧠 Pro Knowledge Checks
  • 107 hands-on knowledge checks
  • Save & load your work
  • CSV export & scenario comparison
  • ⚙️ Process & Staffing
  • Unlimited processes & facilities
  • Monte Carlo simulation
  • Manpower optimization solver
  • 📋 Daily Operations
  • Daily Playbook & adherence tracking
  • Action item tracking & Kanban board
  • Engineering Task Tracker (My Week + My People)
  • Performance trends (7/14/30 day)
  • Pareto & root cause analysis
  • Full report & audit history
  • Save templates & auto-save
  • Training progress & badges
  • Up to 5 team members
Start 7-Day Free Trial →

No charge for 7 days. Cancel anytime.

Team
$29.99/mo
Scale across your floor. Up to 15 members.
  • Everything in Pro, plus:
  • 👥 Team Management
  • Up to 15 team members
  • Role-based access (supervisor, manager, admin)
  • Manager view across all members
  • Team-wide action item management
  • 🏭 Multi-Facility
  • Multi-facility support
  • Live activity feed & cross-team task assignment
  • 5S & Safety audit history across team
  • Leader Standard Work team adherence
  • 📦 Extras
  • Shared template library
  • Outlook sync (.ics export for team plans)
  • Priority support
Upgrade to Team →

Ready to model, simulate,
and optimize?

The Flow Modeler is free to try. When you're ready for the full toolkit — pro analysis tools, training tracks, and templates — start a 7-day Pro trial. No credit card required.

Open Engineering Workbench →