Tools that run offline

Process Modeler

Staffing and throughput for one multi-step flow, such as a line, a pick, pack and ship flow, or a repair process: who goes where, what the bottleneck is, what output you get.

The question

How many people, where, and what output?

You model

Steps, streams, headcount by team

Best for

Assembly lines, fulfillment and repair flows, office processes

Runs as

One HTML file, any browser

Mixed Shop Modeler

Resource load in a high-mix or repair shop: many parts or work order types, routings and setups across shared machines, test stands, and bays.

The question

Do my machines and stands have room for this mix?

You model

Machines or stands, parts or work orders, routings, setups

Best for

Job shops, high-mix machining, repair shops with shared test stands

Runs as

One HTML file, any browser

Floor Simulator

Sizing a whole line at a rate: machines, people, Max rate and flow time, simple first, with a live 2D and 3D floor.

The question

What does the whole line look like at this rate?

You model

Work centers and hrs first; operations, parts and the floor when you turn them on

Best for

New production lines, rate changes, layouts

Runs as

One HTML file, Chrome or Edge

VSM Pro

The value stream tool: a guided first map for anyone walking an area, then current and future state, demand and takt, and what-if on the numbers, for production, order-to-delivery, or repair flows.

Made for

Anyone mapping a real area, first time or fiftieth

How it works

Guided mode walks the build; Simple and Advanced add future state and what-if

Files

Opens Class Workbook and old Floor Map files

VSM Class Workbook

Learning or teaching value stream mapping: stage-by-stage build, metrics, and a class guide.

Made for

Classes learning the method

How it works

Stage-by-stage classic map with teaching notes

Files

Saves files that open in VSM Pro

Line Designer Pro

Designing or rebalancing a line station by station against takt, with crews and work elements, plus a Quick mode for first answers on one page each.

The job

Quick checks, then design the line station by station

Output

Takt, station plan with crews and elements, leveled line, WIP cap

Yamazumi Balancer

Stacking work elements per station against takt and rebalancing them, Before against After.

The job

Rebalance work elements on stations that exist

Output

Yamazumi chart, Before vs After

Flow Starter Kit

Moving one area to flow, on the floor, in the warehouse, or in a repair shop, with your numbers, a checklist, a two-day workshop and daily floor scripts.

The job

Move one area to flow

Output

Checklist, workshop, daily scripts

A3 Pro

Writing and printing a one-page A3: problem, analysis, countermeasures, follow-up.

Use it to

Tell the whole story on one page

Comes first

After the root cause is known

5 Why Pro

Getting from a problem statement to verified root causes and the actions that close them.

Use it to

Find and prove the root cause

Comes first

Yes, then send into A3 Pro

5 Why + A3 Pair

Running root cause and writing the A3, with the work carried from one into the other.

Use it to

Do both, with Send to A3 between them

Comes first

Start in 5 Why Pro

Flow Basics Self-Study Worksheets

For engineers and leads learning flow on their own: eight worksheets and a field check, idea to practice.

Who uses it

One person learning on their own

What is in it

Eight worksheets and a field check with worked examples

Flow Basics Trainer Pack

Running a one-day flow basics class: facilitator screens, slides, the Lego game, and the participant and supervisor sheets.

Who uses it

The trainer, for a whole class

What is in it

Class Kit, slides, Lego game pack, worksheets, supervisor sheets, classroom print license

IE Templates Pro

All eight IE templates in one binder file, for people who use several of them.

IE Calculator Pro

All fourteen IE calculators in one workbook file, for people who use several of them.

Everything Bundle

Owning every available tool outright with one purchase. To use the tools without buying them, see the plans.