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How we use AI · CI toolkit

The printable CI toolkit.

Blank, fill-in versions of every continuous-improvement tool in the method, grouped by Plan, Do, Check and Act. Print it, grab a pencil, and fill one in over coffee. Pencil beats perfect. Many of the tools here come from DMAIC (Six Sigma's Define, Measure, Analyze, Improve, Control), and we're grateful for them.

24 tools, each on its own page. Filled-in examples live in the method.

1

Personal SIPOC

CI tool · SIPOCP · Plan

A living map of your life's work, like a will or a living trust: where the work comes from, what it is, how you handle it, what good looks like, and who it's for. Fill left to right in about twenty minutes, then review it on a set schedule (we suggest quarterly) and update it as life changes.

Reviewed on:
Next review (quarterly?):
S · Suppliersroles, channels, plansI · Inputswhat actually shows upP · Processfive steps or fewerO · Outputswhat “good” looks likeC · Customerswho it serves
Capture →

Triage →

Decide →

Do →

File & improve

Quality · the CTQ

how we expect the thing to be done, built in at the source

Delivery

when it has to arrive, and how often

Quality and delivery measures become the requirements that drive our notifications and the daily newspaper, which feeds the kanban and the daily report-out. Check: does every output serve a named customer? If not, drop it or park it.

See the example →
2

Stakeholder analysis

CI tool · Stakeholder analysisP · Plan

Once you know your customers, map what each one needs from you. Start with the C column of your SIPOC. Ideas: family, spouse, work team, close friends, guests, and yourself.

WhoWhat they need from meHow oftenHow I keep them in the loop
Myself
See the example →
3

Voice of the Customer → CTQ tree

CI tool · VOC → CTQ treeP · Plan

Listen first: for each customer from your SIPOC, write what they would actually say (their words, feedback, what you notice) and the need underneath. Then write the CTQ, critical to quality: a plain, checkable standard for “good” that also goes into the SIPOC's quality column.

WhoWhat they'd saytheir wordsWhat they really needCTQhow I'll know it's goodTarget
Myself

A good CTQ is something you could check on a calendar or a count. “Be more present” → “dinners without screens, most nights.”

See the example →
4

Macro plan (Hoshin kanri)

CI tool · Macro plan (Hoshin kanri)P · Plan

Every small thing points up (hoshin kanri). Write top to bottom; each level should name the one above it serves.

Future self · 3+ years

Vision · mission · values

Vision: an ordinary Tuesday, three years out. Mission: this season, one line. Values: three to five filters.

Macro plan · this year

Three or four themes (big rocks)

90-day plan · this quarter

A few rocks

RockServes themeDone when
This week · one page

Blocks that move a rock

Plus: what's waiting on you, and the day you keep free.

See the example →
5

Baseline & data collection plan

CI tool · Baseline & data collection planP · Plan

Decide exactly what counts before you measure. Then measure two ordinary weeks, before you change anything.

Baseline from:
to:
Reviewed in:
MeasureOperational definitionexactly what countsSourceWho collectsHow oftenBaseline

Write the definition before you look at the number.

See the example →
6

A3 brief & mind map

CI tool · A3 brief & mind mapP · Plan

An A3 can stand in for a whole plan-do-check-act cycle on one page. Put the one-off in the middle. Fill the branches before you hand it to a deep-work partner; the branches become the brief's headings.

The topicone line
Why it mattersthe outcome
Who it's forthe reader or user
What I already haveinputs, drafts, notes
Must-havesnon-negotiables
Keep outprivate, off-limits, out of scope
Done whenthe finish line
Backgroundwhy nowCurrent statewhat I haveGoaldone whenPlansteps, whoCheckhow I'll know

The A3: the same brief on one page. The mind map's branches fill it in.

See the example →
7

Virtual 5S

CI tool · Virtual 5SD · Do

Files, inboxes and notes, organized like a well-run workshop. Do the first pass once; then keep the weekly shine.

StepWhat it meansMy actionDone
1 · SortDelete or archive what you don't need☐
2 · Set in orderOne home for each kind of information☐
3 · ShineWeekly clean-up: Downloads, desktop, inbox☐
4 · StandardizeNaming, and where things go☐
5 · SustainA routine that keeps it tidy☐

The weekly shine · 15 min

  • Downloads emptied
  • Desktop holds this week's work only
  • Inbox sorted into piles
  • Stray files renamed to the standard
  • Captures filed to a lane

My naming standard

Try: date · lane · what it is. My shine day and time: ____________

See the example →
8

Standard work

CI tool · Standard workD · Do

The current best way to run a routine, written down. If a step has a clear “done when,” a routine can eventually run it for you.

Routine:
Owner:
Last revised:
TimeStepDone whenCan a routine run it?
See the example →
9

Poka-yoke & jidoka

CI tool · Poka-yoke & jidokaD · Do

For each routine or helper, name what could leave the house (send, spend, book, delete), how we make the safe path the easy one, and where it stops and asks for us.

Routine or helperWhat could leave the housePoka-yokehow the safe path is the easy oneJidokawhere it stops and asksIf it breakshow it tells us

Our one rule: if it leaves the house, it waits for a yes. When unsure, the item goes in “Needs you.”

See the example →
10

Kanban board & WIP limits

CI tool · Kanban & WIP limitsD · Do

One card per item. Set a small limit on Doing and on Waiting on you; when a column is full, nothing new moves in until something moves out.

Week of:
Doing limit:
Waiting-on-you limit:

Captured

Doing · limit ___

Waiting on you · limit ___

Done

The Level-week planner is the same idea at a different level: the week instead of the day-to-day items. Also see Visual management & andon in Act.

See the example →
11

Level-week planner (Heijunka)

CI tool · HeijunkaD · Do

Spread the week evenly: a little deep work, admin, people time and home each day, instead of spikes. Keep one day free.

Week of:
DayDeep workAdminPeopleHomeLoadlight · ok · heavy
Mon
Tue
Wed
Thu
Fri
Sat
SunKept free · being present

Any day marked heavy? Move one block to a light day before the week starts.

Same idea as the Kanban board and other visual boards, at a different level: the whole week.

See the example →
12

RACI chart

CI tool · RACI chartD · Do

One row per recurring task. Exactly one A per row. If it leaves the house, the A is you.

TaskMeChief of staffSpecialistSpecialist
R Responsible · does the workA Accountable · owns it, gives the yesC Consulted · asked beforeI Informed · told after
See the example →
13

FMEA-lite

CI tool · FMEA-liteD · Do

For each agent or routine: what could go wrong, how bad, how likely, and the guardrail that prevents it. Re-check when a new bot joins the team.

Agent / stepWhat could go wrongEffectSeverityH · M · LLikelyH · M · LGuardrail

Standard guardrails: drafts not sends (poka-yoke) · stops and asks (jidoka) · heartbeat, fail loud.

See the example →
14

Control Tower KPI sheet

CI tool · Control TowerC · Check

One page that tells you whether the system is working. Pick three to six measures, tie each to your future self or a macro-plan theme, and review them weekly in the week-ahead, not daily. This is also our Check: see where we are and act on anything not performing the way we expect. Your first reading, before you change anything, is your baseline.

Week of:
Reviewed in:
MeasureWhy it matterswhich theme it servesTargetThis weekStatusgreen · amber · redTrend
G · A · R↑ → ↓
G · A · R↑ → ↓
G · A · R↑ → ↓
G · A · R↑ → ↓
G · A · R↑ → ↓
G · A · R↑ → ↓

By specialist · one number each

Color rules

  • Green: handled, no action
  • Amber: needs a glance
  • Red: needs a decision

Ideas: routines on time · decisions waiting on me · inbox calm · rocks on track · first-pass approvals · days kept for being present · time where I meant it.

See the example →
15

Flow metrics

CI tool · Flow metricsC · Check

Pick a handful of tasks or items. For each one, jot when it was asked for, when we started it, when it was done, and how much of that was real working time. Bring the averages to the Control Tower KPI sheet.

Week of:
Reviewed in:

Cycle time

How long one task takes from the day we start it to the day it's done. A long one can point to a bottleneck or a place work keeps stopping.

Process time

The time we actually spend working on it, without the waiting.

Lead time

How long from when it's asked for to when it's delivered. A long one can show where delays hide along the way.

Task or itemAsked fordateStarteddateDonedateProcess timehands onCycle timestart → doneLead timeask → done
Average cycle time:
Average lead time:
Carryover into next week:

Short cycle time plus low carryover means work is flowing. If carryover climbs, we take on less, not more.

See the example →
16

Say vs. do review

CI tool · Say vs. do reviewC · Check

Do it once before you change anything to capture a baseline, then monthly or quarterly to check and to close the loop. List what you say matters (from your future-self values), then pull the facts from your calendar or a time audit. No grades: one observation, one small experiment, check again next month.

Month / quarter:
Facts from:
Check again on:
What I say mattersRankHours this month% of timeGapbigger · smaller · fineOne experiment

One observation

The biggest gap, in neutral words. Facts, not judgment.

One experiment for next month

Small, specific, on the calendar. Then check it (PDCA).

See the example →
17

Gemba / waste walk (8 wastes)

CI tool · Gemba / waste walkC · Check

Gemba means go and look. Walk one real loop with real data (screenshots, a week of inbox and calendar). For each step, write what really happens and tag the waste with a DOWNTIME letter.

Process walked:
Date:
Real data used:
StepWhat really happensWasteDOWNTIME letterIdea to remove it
Capture
Triage
Decide
Do
File
D DefectsO OverproductionW WaitingN Non-utilized talentT TransportationI InventoryM MotionE Extra processing
See the example →
18

Pareto tally (80/20)

CI tool · Pareto 80/20C · Check

Tally a month of one thing (emails by kind, tasks by type, hours by lane). Sort biggest first, add a running total, and circle the few that make about 80%.

What I'm tallying:
Period:
CategoryTallyCount%Running %

The vital few

One rule that handles them

A filter, a pile, a routine, or an unsubscribe. AI proposes; you approve.

See the example →
19

5 Whys

CI tool · 5 WhysC · Check

RCA (root cause analysis), part one: 5 Whys pairs with the Fishbone / CEDAC sheet to dive deeper into causes. When something slips, ask why until you reach a cause you can fix. Stop when the answer is a process, not a person.

What happened:
When:
How often:
Why?Because…Evidence
Why 1
Why 2
Why 3
Why 4
Why 5

Root cause

Countermeasure · check on

Then check it next month (PDCA).

See the example →
20

Fishbone / CEDAC

CI tool · Fishbone / CEDACC · Check

RCA (root cause analysis), part two: CEDAC extends the fishbone and pairs with 5 Whys to dive deeper into causes. Write the problem in the middle. Brainstorm possible causes under each category, then circle the likeliest and test it with 5 Whys.

Method

the routine and its steps

Tools

apps and bots

Inputs

what arrives, from where

The problem →

People

me, my spouse, the team

Timing

rhythms and schedules

Environment

busy seasons, travel weeks

See the example →
21

Control plan & signal vs. noise

CI tool · Control planA · Act

For each Control Tower measure: what normal looks like, who checks it, the signal that means act, and the reaction.

MeasureNormal rangeChecked by · how oftenSignal: act when…Reaction

Signal vs. noise: one odd week is noise. A run of three drifting the same way, or a point outside the range, is a signal.

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22

Visual management & andon

CI tool · Visual management & andonA · Act

One glance, not a read. Sort this week's items by color, put anything red in “Waiting on you,” and keep the page short.

Week of:

Waiting on you

Green · handled

Amber · needs a glance

Red · needs a decision

Mon
Tue
Wed
Thu
Fri
Sat
Sun
See the example →
23

Leader standard work & tiered rhythms

CI tool · Leader standard work & tiered rhythmsA · Act

A steady rhythm of check-ins keeps the system honest. For each tier, write when it happens, what we look at, who brings the numbers, and how we know it's done.

TierWhenWhat we look atWho brings itDone when
Tier 1 · Daily
Tier 2 · Weekly
Tier 3 · Monthly
Quarterly · the map

Ideas: a morning brief · a week-ahead · a monthly say-vs-do review · a quarterly SIPOC check-in. Keep one day free, away from screens.

See the example →
24

PDCA feedback log

CI tool · PDCA feedback logA · Act

PDCA is kaizen at its core. Every time you edit or turn down a draft, jot what you changed and what the system should keep. Then save it where your AI will read it next time.

PlanAI drafts from notes
DoI review: yes / edit / no
CheckWhat I changed or rejected
ActSave as style, rule or preference
DateDraft / taskCheck: what I changed or rejectedAct: the lessonSaved asstyle · rule · preference

Examples: “warmer, shorter” → style · “never say X” → rule · “always cc Y” → preference.

See the example →