LEAD360
Lean Management
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Lead 360

Home

Set who is using this system — the name and division appear in the header and on every printed Kaizen and A3 sheet.

Setup

Things you set once. Pick one to open it.

Organisation

Leave the division blank if the system covers the whole company. The form number prints on Kaizen sheets — clear it if your forms have no reference.

Data & backup

Everything you enter lives in this browser. Back up regularly — a cleared browser profile takes the data with it. The file also moves your workspace to another machine.

Login access

This is a policy setting, not security. Lead 360 runs entirely inside this browser with no server behind it, so anyone holding the file can bypass the check. Use it to keep the right names on records and to have the list ready for the day a real backend is added — do not rely on it to keep anyone out.

Library

Put a book on the shelf — a title, a cover image, and either the PDF itself or a link to it. It appears in the Library tab straight away.

Admin control

For the IT head. Sets what this copy of Lead 360 shows and who may do what, and keeps a record of activity. Soft controls only — with no server behind the app these hide, lock and record; they cannot stop someone determined to edit the file.

Stage 01 · Workforce Manpower Time Plan

WMTP register

The starting point. Each section tab is an SFG station the finished good flows through (PCB → CT → AC → CAC …). Import your WMPT workbook to refresh every position, add positions on any line, or click + SFG station to add a new stage — the whole register (grade split, cycle time, UPH, efficiency, takt) then builds itself for that station.

Saved

Positions

Enter Cycle time (seconds) to get UPH = 3600 ÷ CT and UPPH = UPH ÷ head count. The slowest station on each line is auto-flagged Bottleneck; set Status to override. Colours follow the legend above; click a colour to filter.
Stage 02 · Value stream mapping

Layout / VSM

The current layout builds itself from the WMTP register in sequence — no manual placement. Each process is coloured by status (bottleneck from the slowest cycle time on its line) and shows CT, UPH, UPPH and manpower. Switch to Future and set target UPH and manpower; the gap is your improvement case.

Value stream summary

Current pulls UPH from cycle time (or the Master Plan where CT isn't entered) and manpower from head count. Future uses your targets. Saved manpower and UPH gain are summed across every station shown.
Stage 03 · Division improvement board

Master Plan

Auto-built from the WMTP register and your VSM. Each station's improvement is classified into an opportunity type from its nature, cycle-time status and the current→future gap, then grouped and colour-coded — so the whole division's station plans sit in one window.

Division summary

Click an opportunity type to isolate it. Bottleneck stations and planned manpower savings drive the classification; set the Opportunity cell on any row to override.
Stage 04 · Define the work

Project scope

Describe the line and the deliverables. The effort model reads these numbers directly — station and operator counts, model variants, and the complexity multiplier drive every duration downstream.

Product family

Variants & complexity

Complexity: 1.0 simple line, minimal variation · 1.5 standard line, moderate variation · 2.0 complex line — multiple variants, frequent adjustments or specialised equipment.

Stations & operators

Deliverables

Only the deliverables you switch on are scheduled and costed.

Suggested owners from skill matrix

Stage 05 · The engine

Effort calculator

Standard-time estimates turned into minutes, hours and working days per deliverable. Hours round up to the nearest half; days assume an 8-hour shift. Change the scope and this recomputes.

Standard times · calculation logic the engine

These observation-based standard minutes drive every estimate. Adjust them to your own time study and all deliverables, days and the timeline recompute.

Per-deliverable effort

Deliverable
Minutes
Hours
Days

Base analysis tasks

Task
Minutes
Hours
Days

Formula assumptions

  • Engineering effort estimates assume one engineer unless specified otherwise.
  • Estimated durations are based on standard process observation methods.
  • Timeline durations exclude weekends and company holidays (if applicable).
  • Changes to the standard times above may affect calculated results.

Complexity definitions

  • 1.0 — Simple production line with minimal variation.
  • 1.5 — Standard production line with moderate variation.
  • 2.0 — Complex line involving multiple product variants, frequent adjustments or specialised equipment.
Stage 07 · Scheduled plan

Timeline

Pick a saved project and its complete activity schedule builds itself from the effort model — weekends excluded, milestones between phases. Add a start date; the app calculates the rest.

◆ milestone · coloured bars are working-day activities, shaded by risk. Effort only schedules just the analysis work, so the timeline length equals the effort days (weekends skipped). Full plan adds the reference implementation phases — kick-off, review/approval meetings, trials and sign-off — after the analysis.
Portfolio · saved work

Projects

Scoped projects with their effort and schedule snapshot, and a per-leader rating that grows as projects are completed. Switch to the log for a summary table.

Stage 08 · A3 report

A3

A one-page PDCA report per project — background, current state, targets, the key activities from the plan, and before → after results. Auto-numbered and built entirely from the project's own data.

✨ Gemini
Executive · savings and projects

Executive report

What the improvement programme has returned, against what it promised and what it was asked for. Every figure is read live from the project register — nothing here is entered twice. Hard and soft savings are kept apart on purpose: hard is cash out of the P&L, soft is capacity released, and adding them into one headline is how a programme talks itself into a number it cannot bank.

Team · skills roster

Resources

The team profile that feeds Scope owner-suggestions and Timeline Owner / Support. Add each person's lean-tool skills at level 1–5 from the House of Lean; the app ranks people by skill when suggesting owners.

Lean analysis · House of Lean tools

Analysis

Kanban board

Kanban board

Every open thread in the system on one wall — improvement projects, the 5S rollout, red tags, audits due, kaizen suggestions and analyses. Cards build themselves from the modules; nothing is entered twice.

MFCA · ISO 14051

Material flow cost accounting

Conventional costing prices the product and lets the waste disappear into overhead. This prices the loss — the same money, told the other way round, so the material you throw away has a number on it.

Library

Library

The reading behind the tools. Shelved by subject, with what each book is actually for — so a recommendation comes with a reason, not just a title.

Performance dashboard

KPIs

One screen across the whole system — the manpower register, the improvement pipeline, 5S and Kaizen. Everything here is calculated live from what the other tabs hold.

5S · workplace organisation

5S

Sort, set in order, shine, standardise, sustain — the plan, the red tags, the audit and the zones, so the workplace holds the state you set it to instead of drifting back.

Improvement suggestion / Kaizen system

Kaizen management

Ideas from the floor, scored the same way every time, approved through one chain and rewarded by band — so a good idea is recognised for what it returns, not for who raised it.