100+ Continuous Improvement SOPs (Excel XLSX)

BENEFITS OF THIS EXCEL DOCUMENT

1. Provides a comprehensive framework for deploying a standardized Continuous Improvement system across your organization.
2. Delivers 150 fully structured Lean, Kaizen, Six Sigma, Quality, Safety, and Digital CI SOPs in an editable Excel format to accelerate execution and ensure consistency.
3. Enables organizations to drive measurable performance improvement, governance, and sustainability through clearly defined roles, workflows, KPIs, and controls.

CONTINUOUS IMPROVEMENT EXCEL DESCRIPTION

This product (100+ Continuous Improvement SOPs) is an Excel template (XLSX), which you can download immediately upon purchase.

Curated by McKinsey-trained Executives

100+ Continuous Improvement SOPs Library (Excel Template)

The Ultimate Lean, Six Sigma & Operational Excellence SOP System

If you are serious about Lean transformation, Six Sigma execution, and scalable Continuous Improvement, this 100+ Continuous Improvement SOPs Library is the most comprehensive, ready-to-deploy solution available.

This Excel-based SOP Template Library delivers 150 professionally structured Continuous Improvement SOPs, covering Lean, Kaizen, Six Sigma, Quality, Safety, Digital CI, Governance, and Culture – all standardized, editable, and immediately usable across manufacturing, operations, service, healthcare, logistics, and enterprise environments.

Each SOP is fully documented and standardized with:
•  Purpose
•  Scope
•  Owner / Role
•  Inputs (Required Information & Documents)
•  Process Steps (Detailed Workflow)
•  Outputs / Deliverables
•  KPIs / Success Metrics
•  Risks / Controls
•  Review Frequency

This library eliminates months (or years) of SOP development work and gives you a proven Continuous Improvement operating system you can scale across teams, sites, and regions.

Why This SOP Library Dominates
•  ✅ 150 end-to-end Continuous Improvement SOPs
•  ✅ Lean, Kaizen, Six Sigma, Quality, Safety & Digital CI included
•  ✅ Excel format – fully editable and customizable
•  ✅ Built for audits, ISO alignment, and enterprise governance
•  ✅ Ideal for CI leaders, OpEx managers, Black Belts, and PMOs

If you want faster improvements, stronger governance, measurable cost savings, and repeatable execution, this SOP library is your competitive advantage.


📚 FULL CONTINUOUS IMPROVEMENT SOP LIBRARY
CLUSTER 1 – Lean Foundations & Daily Management
1. Daily Management System (DMS) Setup
2. Leader Standard Work (LSW)
3. Gemba Walk Procedure
4. Visual Management Board Creation
5. Performance Huddle / Tiered Meetings
6. Standard Work Documentation Method
7. 5S Implementation & Auditing
8. Process Observation (Waste Walk)
9. Hour-by-Hour Tracking
10. Kaizen Suggestion System

CLUSTER 2 – Kaizen & Rapid Improvement
11. Kaizen Event Planning
12. Kaizen Event Facilitation
13. Kaizen Report-Out Requirements
14. Kaizen Follow-Up & Sustainment
15. Rapid Improvement Workshop (RIW)
16. Problem Discovery Workshops
17. Everyday Lean Ideas Intake
18. Kaizen Newspaper Tracking
19. 30/60/90 Kaizen Review
20. Improvement Idea Prioritization

CLUSTER 3 – Six Sigma Project Execution
21. DMAIC Project Chartering
22. Voice of Customer (VOC) Capture
23. Critical-to-Quality (CTQ) Definition
24. SIPOC Creation
25. Data Collection Plan
26. Measurement System Analysis (MSA)
27. Root Cause Verification
28. Pilot Study Execution
29. Control Plan Development
30. Project Tollgate Reviews

CLUSTER 4 – Problem Solving Methods
31. 5 Whys Analysis
32. Fishbone Diagram Facilitation
33. 8D Problem Solving
34. PDCA Cycle Execution
35. A3 Problem Solving
36. Cause-and-Effect Matrix
37. Failure Mode and Effects Analysis (FMEA)
38. Control Impact Matrix
39. Fault Tree Analysis
40. Countermeasure Selection

CLUSTER 5 – Process Mapping & Standardization
41. Value Stream Mapping (VSM)
42. Current-State Process Mapping
43. Future-State Process Design
44. Swimlane Mapping
45. Makigami Process Analysis
46. Standard Operating Procedure (SOP) Writing
47. Work Instruction Development
48. Process Step Time Study
49. Capacity Analysis
50. Task Breakdown Sheets

CLUSTER 6 – Root Cause Analysis & Troubleshooting
51. Defect Characterization
52. Is/Is Not Analysis
53. Pareto Analysis
54. Rework and Scrap Analysis
55. 5M/1E Assessment
56. Run Chart Troubleshooting
57. Error Cause Analysis
58. Process Containment Procedure
59. Interim Workarounds Management
60. Corrective Action Validation

CLUSTER 7 – Data, Metrics & Performance Monitoring
61. KPI Definition Procedure
62. KPI Tree Creation
63. Data Integrity & Validation
64. Real-Time Data Capture Standards
65. Dashboard Development
66. Performance Trend Analysis
67. Statistical Process Control (SPC)
68. Control Chart Selection
69. Metric Variance Investigation
70. KPI Cascade Process

CLUSTER 8 – Waste Reduction & Flow Improvement
71. 7 Waste Identification
72. Bottleneck Identification
73. Takt Time Calculation
74. Cycle Time Optimization
75. Load Balancing / Line Balancing
76. Single-Minute Exchange of Die (SMED)
77. Cellular Layout Design
78. WIP Inventory Analysis
79. Flow Efficiency Measurement
80. Pull System Conversion

CLUSTER 9 – Standard Work & Training Systems
81. Standard Work Creation
82. Standard Work Audit
83. Work Combination Table
84. Skills Matrix Creation
85. Training Within Industry (TWI) – Job Instruction
86. Training Effectiveness Verification
87. Onboarding Training Standards
88. Role-Based Competency Assessment
89. One-Point Lesson (OPL) Creation
90. SOP Revision Control

CLUSTER 10 – Quality Management & Defect Prevention
91. Quality Checkpoint Design
92. Poka-Yoke Design
93. Quality Gate Reviews
94. First Article Inspection
95. Advanced Product Quality Planning (APQP)
96. Supplier Quality Nonconformance Reporting
97. PPAP Submission Process
98. Customer Complaint Handling
99. Corrective/Preventive Action (CAPA)
100. Layered Process Audits (LPA)

CLUSTER 11 – Project & Portfolio Management
101. CI Portfolio Prioritization
102. Project Intake & Screening
103. Impact/Feasibility Scoring
104. Resource Assignment Process
105. Project Timeline Baseline
106. Cross-Functional Team Alignment
107. Stakeholder Update Process
108. Risk and Mitigation Planning
109. Change Management Readiness
110. Lessons Learned Capture

CLUSTER 12 – Safety, Reliability & Risk Reduction
111. Job Hazard Analysis (JHA)
112. Workplace Risk Assessment
113. Safety Kaizen Events
114. Near-Miss Investigation
115. Safety Standard Work
116. Lockout/Tagout Improvement
117. Ergonomics Evaluation
118. Hazard Elimination Prioritization
119. Reliability-Centered Maintenance (RCM)
120. Preventive Maintenance Optimization

CLUSTER 13 – Digital & Automation-Based CI
121. Digital Process Mapping
122. Robotic Process Automation (RPA) Scoping
123. Digital KPI Tracking Setup
124. IoT Sensor Data Monitoring
125. Predictive Analytics Workflow
126. Digital Workflows & Approvals
127. Paperless Process Conversion
128. MES/ERP Data Quality Checks
129. Digital Visual Management Board
130. Automation ROI Assessment

CLUSTER 14 – Culture, Communication & Engagement
131. CI Competency Framework
132. CI Onboarding Orientation
133. Employee Idea System Governance
134. Recognition Program for Improvements
135. Coaching for CI Leaders
136. Cross-Functional Collaboration Procedure
137. Internal CI Communications
138. Lunch-and-Learn Facilitation
139. CI Maturity Assessment
140. Celebration of Wins Protocol

CLUSTER 15 – Governance, Sustainability & Audits
141. CI Program Governance Model
142. CI Steering Committee Procedure
143. Annual CI Planning Cycle
144. Standardization Across Sites
145. Audit Scheduling & Execution
146. Process Compliance Reviews
147. Sustainability Review Procedure
148. Performance Review of CI Leaders
149. Long-Term Tracking of CI Benefits
150. Cost Savings Verification & Finance Sign-Off




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Source: Best Practices in Continuous Improvement Excel: 100+ Continuous Improvement SOPs Excel (XLSX) Spreadsheet, SB Consulting