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Process Step Elimination Worksheet

Challenge every step in your process. Answer tough questions that push you to eliminate — not optimize — unnecessary work. The fastest step is the one you don't do.

⏱️
45-90 min
Facilitation Time
👥
2-4 engineers + operator
Team Size
📋
Current process map + this sheet
Materials
🎯
Before optimizing — always eliminate first
When to Use
💡 Why This Tool Matters

Engineers default to optimizing bad steps instead of removing them. A step that takes 3 minutes can be optimized to 2 minutes — or eliminated entirely. This worksheet forces the hard question: "Does this step need to exist at all?" Toyota's principle is clear: the best process is the shortest process. Every step you eliminate is a step that can never break, never slow down, and never need resources again.

⚡ Facilitator Pro Tip

Challenge everything. When someone says 'we've always done it this way,' that's your biggest elimination opportunity. The most dangerous waste is the waste nobody questions because it looks like real work.

List every step in the process. For each one, answer the hard questions honestly. The goal is to eliminate as many steps as possible — not to make bad steps faster.
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Rule #1: If a step doesn't directly add value the customer pays for — it's a candidate for elimination.
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Rule #2: Don't optimize a step that shouldn't exist. Kill it first, optimize later.
Rule #3: If two steps can become one — combine them. The best handoff is no handoff.
🪓 ELIMINATE — Remove entirely 🔗 COMBINE — Merge with another step ✅ KEEP — Truly adds value ⚠️ QUESTION — Needs deeper review
Eliminate
0
0 min saved
Combine
0
0 min saved
Keep
0
0 min
Question
0
0 min at risk
Elimination Rate
0%
0 min saved
These questions force you to think harder about elimination. Don't skip them.
Q1
Q2
Q3
Q4
Q5
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