Free Discrete Manufacturing tools

172 templates, calculators, worksheets and reference tables. Each runs in your browser and exports to PDF, Excel, Word or CSV.

Templates and forms (10)Worksheets (18)Calculators and simulators (99)Reference tables (21)Code and query generators (3)Checklists (8)Assessments (13)

Templates and forms

Infor VISUAL Engineering Change Notice Template

A fill-in ECN form covering part revision, engineering master and BOM changes, open work order impact and approvals, ready to export.

Job Shop RFQ Intake Form Template

A one-page request for quote intake form so every RFQ reaches the estimator with the same information before anyone opens JobBOSS, E2 Shop System or Global Shop Solutions.

Manufacturing KPI Dashboard Template

A one-page monthly KPI dashboard for plant reviews: delivery, quality, inventory, cost and safety with target, actual and commentary.

Monthly Operations Review Report Template

Fill-in monthly operations review covering delivery, quality, inventory and cost, with actions and decisions required.

Kaizen Event Charter Template

Fill in the fields and generate a one-page charter for a kaizen blitz, with scope, targets, team, timeline and approvals.

Daily Tier 1 Huddle Meeting Template

Record the daily Tier 1 huddle: safety, quality, delivery, cost, problems and actions, with owners and due dates.

Risk Response and Contingency Plan Template

A document for the top risks on a program: how you will respond, what triggers the fallback and who decides.

CNC Chip Load Reference Worksheet

A printable chip load starting-point chart for carbide end mills with a fill-in record for the cutting data you finally prove out.

Returnable and Non-Returnable Gate Pass Template (India Factory)

A printable gate pass for tools, dies, samples and materials leaving the plant, with return tracking and approvals.

COO Monthly Operations Report Template

A one to two page monthly operations report: headline KPIs, highlights, problems, actions and decisions needed from leadership.

Worksheets

Job Shop Quote Worksheet

Quote a machined part operation by operation: setup hours, run minutes per piece, shop rate and material. Totals the cost and shows the price at a target margin.

KPI Target Setting Worksheet

Compare baseline, best recent result and target for each KPI, with gap and improvement percent computed per row.

SMED Changeover Element Analysis Worksheet

List each changeover element, classify it as internal or external, and record planned time savings with totals.

Value Stream Map Data Worksheet

Fill in the data box for each process step of your current-state map and get total lead time, value-added time and process cycle efficiency.

Yamazumi Line Balancing Worksheet

Record station times by value-add, necessary and waste, compare each to takt time and see how balanced the line is.

Lean 8 Wastes Observation Log

Log waste by type and area, estimate daily minutes and cost, and see which wastes deserve a kaizen first.

Master Production Schedule Template

A weekly MPS grid with forecast, customer orders, projected on hand and planned production quantity for a single product.

Sheet Metal K-Factor Worksheet

An editable log of verified K-factors by material, thickness, radius and angle, with bend allowance and radius-to-thickness ratio computed on every row.

Steel Plate Cut List Weight Worksheet

Fill a cut list row by row and get piece weight, line weight and total order weight for plate, sheet and flat parts.

Plate Nesting Utilization and Material Cost per Part Worksheet

Enter sheet size, thickness, density, part area and parts per nest to get sheet weight, utilization percent and material cost per part for each job.

Pharma Stage Yield and Reconciliation Worksheet

Enter input, output, samples and rejects for each manufacturing stage to see yield and unaccounted loss that needs an explanation.

Furniture Cut List and Panel Yield Worksheet

An editable cut list that totals part area and estimates how many board sheets a furniture job needs, exportable to Excel.

Load Shedding Downtime Loss Log Worksheet

An editable outage log that turns grid downtime and generator hours into lost units, lost contribution and diesel cost per shift.

Strategic Initiative Portfolio Tracker Worksheet

Track every improvement and transformation initiative in one table: owner, budget, spend, percent complete, expected benefit and status.

Hoshin Kanri X-Matrix Worksheet

A table-based policy deployment worksheet: link long-term objectives to annual goals, improvement priorities, metrics and owners.

Site Consolidation Decision Matrix Worksheet

Compare plants or footprint options against weighted criteria such as cost, capability, labor, customers and risk. Editable and exportable.

Strategic Initiative Prioritization Scoring Worksheet

An editable scoring table that ranks operations initiatives on impact, strategic fit, effort and risk, with benefit, cost and payback for each.

Automation Candidate Process Scoring Worksheet

List manual processes, enter volume and effort, score rule clarity, data quality and risk, and get a ranked automation shortlist with annual hours at stake.

Calculators and simulators

OEE Calculator (Overall Equipment Effectiveness)

Break your Overall Equipment Effectiveness into availability, performance, and quality, and see how far you sit from the 85% world-class benchmark.

Scrap Rate Cost Calculator

Turn your scrap percentage into an annual dollar figure - including labor and overhead absorbed by scrapped units - and see what each point of improvement is worth.

Takt Time Calculator

Compute the takt time your line must hit to meet customer demand, plus the required hourly rate for supervisors and schedulers.

Cycle Time & Capacity Calculator

Translate cycle time, parallel stations, shift pattern, and realistic utilization into hourly, daily, and annual production capacity.

Inventory Carrying Cost Calculator

Build your true annual carrying cost from capital, storage, insurance, and obsolescence components - and see what an inventory reduction target is worth.

Economic Order Quantity (EOQ) Calculator

Compute the order quantity that minimizes combined ordering and holding cost, with orders per year and total annual cost at the optimum.

Manufacturing Downtime Cost Calculator

Combine lost contribution margin, idle labor, and absorbed overhead into a defensible monthly and annual downtime cost - with recovery effects modeled.

Safety Stock Calculator

Size statistically defensible safety stock using demand variability, lead time variability, and your target service level, then see what that buffer costs to carry.

Reorder Point Calculator

Calculate the reorder point that triggers replenishment at the right moment, including review period coverage, and see the inventory value your ordering policy carries.

Inventory Turnover Calculator

Convert your COGS and average inventory into turns and days on hand, then see how much working capital a realistic turns target would release.

Forecast Accuracy (MAPE) Calculator

Turn your forecast and actual history into MAPE, accuracy, and bias figures, then price what that error is costing you across the year.

Stockout Cost Calculator

Price the full annual cost of stockouts across lost margin, expediting, and downstream customer damage, and see what each point of fill rate is worth.

Make vs Buy Calculator

Compare in-house production cost against fully landed purchase price, including tooling amortization, and find the volume where making beats buying.

Procure-to-Pay Efficiency Calculator

Quantify the labor cost buried in your purchase order and invoice processing, including exception handling, and benchmark your cost per invoice against automation leaders.

Smart Factory ROI Calculator

Convert a targeted OEE improvement into monthly revenue lift, total capex, and payback period across your production lines.

IIoT Sensor Deployment Cost Calculator

Estimate hardware, gateway, installation labor, network upgrade, and annual platform costs for an industrial IoT sensor rollout across your machines.

Predictive Maintenance ROI Calculator

Compare baseline unplanned downtime cost against predictive maintenance monitoring cost to see net annual savings across your asset fleet.

MES Implementation Cost Calculator

Estimate total MES implementation cost across licensing, shop-floor terminal hardware, configuration labor, and ERP integration complexity.

Warehouse Automation ROI Calculator

Compare manual and automated pick times to calculate daily labor hours saved, annual savings, and payback period for a warehouse automation investment.

Energy Efficiency Savings Calculator

Estimate monthly and annual energy savings, net capex, and payback period for common manufacturing energy efficiency measures.

Paperless Shop Floor ROI Calculator

Calculate labor time saved and rework avoided by replacing paper travelers and work orders with digital shop-floor terminals or tablets.

Supply Chain AI ROI Calculator

Estimate year-one ROI and payback for a supply chain AI initiative from forecast accuracy, freight avoidance, and inventory reduction against your spend and implementation cost.

Tariff Impact Calculator

Model how origin-specific duty rates hit your imported cost of goods, how much margin erodes after pass-through, and the price increase needed to hold your target margin.

Nearshoring Cost Comparison Calculator

Compare the fully loaded landed cost per unit across sourcing regions, including freight, duty, lead-time-driven inventory carrying cost, and quality rework.

Logistics Cost Optimization Calculator

Model freight savings from shifting mode mix, consolidating shipments, and cutting accessorial fees against your actual monthly shipment volume and average cost.

VISUAL EOQ and Lot Size Setup Cost Calculator

Compute economic order quantity and see what your current lot size costs per year, with a sweep chart across lot sizes.

Bar Stock Yield and Material Cost per Part Calculator

Work out how many parts come from each bar after cutoff and end loss, how many bars to buy, and the true material cost per part.

Make to Order Promise Date and Lead Time Calculator

Compute the calendar days to promise a customer from material arrival, queue, setup, run hours at your efficiency, and ship time.

Production Run Economic Batch Size Calculator

Find the economic production quantity that balances setup cost against carrying cost when parts are made in house at a finite rate.

Load Shedding Cost Calculator for Manufacturers

Put a monthly rand figure on power outages: generator fuel, maintenance, idle labour and the contribution you could not produce.

Order Backlog Coverage and Book-to-Bill Calculator

Convert backlog into weeks of coverage, compute book-to-bill and project where the backlog goes if orders and shipments stay on trend.

Changeover Reduction (SMED) Savings Calculator

Quantify the annual hours, extra capacity and value released by shortening changeovers with SMED.

Spaghetti Diagram Distance Calculator

Convert the distance you measured on a spaghetti diagram into walking time and annual cost, and compare it to an improved layout.

Little's Law Lead Time and WIP Calculator

Convert WIP and throughput into lead time, process cycle efficiency and the WIP cap needed for a target lead time.

SMED Changeover Reduction Savings Calculator

Turn a setup time reduction target into hours freed, machine cost saved and extra parts per year, with a what-if sweep of the target setup time.

EPEI Every Part Every Interval Calculator

Calculate how often you can make every part on a shared resource given changeover time, demand and run time, and the batch each part needs.

Process Cycle Efficiency Calculator

Calculate process cycle efficiency (value-add time as a share of total lead time) and see how much waiting dominates your flow.

Batch Size vs Lead Time and Setup Share Calculator

Compare the lead time of a batch through several operations with the share of time lost to setup, and find the batch that reaches a target setup share.

Planned Order Offset and Start Date Calculator

Add setup, run, queue, move and safety time to get the lead time offset MRP should use to back schedule a made-in-house order.

CNC Speeds and Feeds Calculator

Turn a surface speed and chip load into spindle RPM and table feed for any end mill, capped at your machine's maximum RPM.

Material Removal Rate Calculator

Calculate milling MRR from width of cut, depth of cut and feed, then estimate the spindle horsepower the cut will need.

Surface Finish Ra to RMS Converter

Convert Ra to RMS in microinches or micrometers and estimate the theoretical Ra a turning insert leaves from feed and nose radius.

Tool Life Taylor Equation Calculator

Use the Taylor equation V x T^n = C to predict tool life at a new cutting speed or find the speed that gives a target tool life.

CNC Spindle Power and Torque Required Calculator

Check whether your machine has enough power and torque for a milling cut before you run it, using specific cutting force kc and drive efficiency.

CNC Thread Milling Feed Rate Calculator

Convert the feed per tooth at the cutting edge into the programmed centreline feed for internal and external helical thread milling.

Ball End Mill Scallop Height and Stepover Calculator

Choose the stepover for 3D finishing so that cusp height stays within your surface finish target, and see the time cost of a finer stepover.

CNC Radial Chip Thinning Feed Compensation Calculator

When radial depth is less than half the cutter diameter the chip is thinner than the feed per tooth. Find the feed that restores the chip thickness you want.

CNC Turning Surface Roughness and Feed Calculator

Connect feed per revolution and insert nose radius to the theoretical surface roughness, and pick the fastest feed that still meets the drawing.

CNC End Mill Deflection Calculator

Predict how far a cutter bends under load, and see why shorter stickout and a larger diameter matter so much for accuracy.

Drill Point Length Calculator

Calculates drill point length for common point angles, the Z depth to program for a full-diameter hole, spindle rpm, feed and drilling time.

Turning Cutting Time Calculator

Estimates turning rpm, feed rate, number of passes, cutting time and metal removal rate for a straight turning cut.

Boring Bar Overhang Ratio Calculator

Checks boring bar overhang to diameter ratio against typical limits and estimates tip deflection under a cutting force.

Knurling Blank Diameter Calculator

Estimates the blank diameter to turn before a formed knurl, the diameter growth, and a diameter that gives a whole number of teeth for clean tracking.

Tapping Torque Calculator

Estimates cutting tap torque, thread engagement and spindle power from thread size, tap drill diameter, material and tap condition.

Turning Surface Finish Calculator (Ra, Nose Radius and Feed)

Theoretical Ra and peak-to-valley height for a turned surface, plus the maximum feed that still meets your drawing's finish callout.

Turning Cutting Power and Spindle Load Calculator

Find cutting force, power at the cut, motor power and spindle torque for a turning pass, and see how depth of cut drives the load.

Drilling Torque, Power and Feed Rate Calculator

Know the spindle rpm, feed in mm/min, torque and power a twist or indexable drill needs before you run it on a small machine.

Lathe Taper Per Foot and Tailstock Offset Calculator

Calculate taper per foot, taper per inch, an approximate half angle and tailstock setover from large and small diameters.

Sheet Metal Bend Allowance Calculator

Enter thickness, inside radius, K-factor and bend angle to get bend allowance, bend deduction and the flat blank length for a single bend.

Press Brake Tonnage Calculator

Estimate the force needed to air bend, bottom or coin a part, then check it against your press capacity and the minimum flange.

Sheet Metal Nesting Yield Calculator

Turn a nest result into yield, scrap percentage, sheets required and material cost per part, with scrap credit.

Punching Force Calculator for Sheet Metal

Estimate the tonnage to punch round holes in sheet metal, including stripping force, die clearance and a machine capacity check.

Sheet Metal Flat Blank Length Calculator

Turn outside leg dimensions and bend data into the flat pattern length, using outside setback, bend allowance and bend deduction.

Press Brake Die Opening and Minimum Flange Calculator

Choose a V-die width by thickness multiplier and check whether your flange is long enough to form without slipping into the die.

Sheet Metal Springback and Overbend Calculator

Estimate how far a bend relaxes after the punch retracts and what tool angle to program to land on the target angle.

Laser Cutting Time per Part Calculator

Break a laser job into cutting, piercing and sheet handling time to get a realistic run time and parts per hour.

Mold Shrinkage Cavity Dimension Calculator

Compute the cavity dimension needed to hit a nominal part size after the resin shrinks, and see how much of the tolerance shrinkage variation consumes.

Injection Molding Cooling Time Calculator

Estimate the cooling time of a molded part from wall thickness, resin thermal diffusivity, melt, mold and ejection temperatures, and see how it drives total cycle time.

Barrel Residence Time Calculator

Estimate how long resin sits in the barrel and how much of the machine capacity a shot uses, to spot degradation risk from oversized presses.

Forging Press Tonnage Estimator

Estimate the press force needed for open die or closed die forging from projected area, flow stress and a shape complexity factor, with a safety margin.

Forging Billet Weight and Yield Calculator

Work out the billet weight needed for a forged part given flash, scale and butt losses, then see yield and net material cost per piece.

Tempering Hollomon-Jaffe Parameter Calculator

Compute the Hollomon-Jaffe tempering parameter and the equivalent time at another temperature, or the temperature that gives the same softening in a target time.

Carburizing Case Depth and Time Calculator

Estimate effective case depth for a carburizing temperature and time using a square-root diffusion model, or solve for the time needed for a target depth.

Casting Riser Sizing Modulus Calculator

Calculate riser diameter, height and volume from casting volume and cooling area, and check the riser has enough feed metal.

Photonics Rolled Throughput Yield Calculator

Multiply stage yields from incoming to final test to get rolled throughput yield, good units, scrap, starts needed for a target and cost per good unit.

Laser Cutting Kerf Compensation Calculator

Work out the kerf offset per side, the programmed toolpath dimension for outside contours, holes and slots, and the material removed by the kerf.

Laser Pulse Overlap and Heat Input Calculator

Work out pulse spacing, overlap and line energy for a scanning or moving pulsed laser from speed, repetition rate, spot size and power.

Recipe Batch Scaling Calculator

Scale a base formula up to a target finished weight, accounting for cook or process loss and the number of mixer batches.

Brix Syrup Blend Calculator (Pearson Square)

Calculate the masses of concentrated syrup and diluent needed to hit a target Brix for a batch, with solids mass and a target Brix sweep.

Refrigeration Product Cooling and Freezing Load Calculator

Estimate the heat to remove from product when chilling or freezing, then convert it to a refrigeration load in kW and tons of refrigeration.

Weight Percent to Molarity Calculator

Convert a w/w percent assay into molarity, molality and the mass of active chemical in a volume.

Agitator Power and Reynolds Number Calculator

Calculate agitator power from power number, speed and diameter, with Reynolds number and kW per cubic metre.

Cutting Room Efficiency Calculator

Measure marker efficiency and true fabric utilization for a lay, and put a cost on the fabric lost between marker and cut piece.

Corrugated Box Compression Strength (BCT) Calculator

Estimate box compression test (BCT) strength from ECT, board caliper and box footprint with the McKee formula, then convert it to a safe stacking height.

Label Roll Length and Outer Diameter Calculator

Enter label size, gap, core and material thickness to get roll length in metres, the finished roll diameter, and the most labels that fit under a diameter limit.

Ink Coverage and Consumption Calculator

Estimate ink usage and cost for a print run from sheet or web area, average coverage, ink laydown in grams per square metre and a waste allowance.

Corrugated RSC Blank Size and Board Yield Calculator

Converts inside box dimensions into the RSC blank size, then shows blanks per sheet, board yield and board cost per box.

Corrugated RSC Blank Size and Web Trim Waste Calculator

Turn inside box dimensions into a regular slotted container blank, see how many fit across your web and what the trim costs you.

Anilox BCM Ink Film Thickness and Consumption Calculator

Convert anilox volume to expected wet and dry ink film, then estimate ink kilograms and cost for a job.

Paper Roll Length, Weight and Run Time Calculator

Estimate how many metres, square metres and kilograms are on a roll and how long it runs on your press.

Polyethylene Bag Film Weight, Gauge and Cost per 1000 Calculator

Work out film grams per bag, bags per kilogram, film yield and cost per 1000 bags for a given gauge and size.

Print Job Makeready, Spoilage and Overs Calculator

Find how many sheets to feed to deliver a good quantity after makeready, running spoilage and postpress waste.

Customer Lead Time Quote Calculator

Estimate the lead time to quote a customer from queue load, setup, run time, material wait, outside processing, transit and a safety buffer.

Plant Capacity Expansion Calculator

Projects future demand, compares it with machine capacity at your target utilization and tells you how many machines to add and what they cost.

OEE Gain Capacity Release vs Capex Calculator

Convert an OEE improvement into extra units, extra margin and avoided capital for a new line, so you can compare improvement with expansion.

Third Shift Addition Economics Calculator

Tests whether adding another shift earns its keep once crew cost, shift differential and fixed overhead are counted, and shows break-even utilization.

Bottleneck Throughput Gain Investment Payback Calculator

Shows how much more you can sell and how fast an investment pays back when a constraint is relieved, capped by the next constraint and by demand.

Overtime vs New Hire Break-even Calculator

Compares chronic overtime, including fatigue-related productivity loss, with the loaded cost of hiring and shows the weekly hours where hiring wins.

Plant Floor Space Requirement Calculator

Rough-cut floor area estimate for a new line or plant from machine count, clearance factor, pallet storage, support space and growth margin.

Reference tables

Job Shop ERP Glossary Reference

Plain-language definitions of job shop terms, with where each one shows up in ERP data.

Manufacturing KPI Formula Reference

A searchable lookup table of the formulas behind common manufacturing and ERP KPIs, with units and typical data sources.

Seven Wastes of Lean (Muda, Mura, Muri) Reference Table

A searchable lookup of the classic wastes with floor examples, the ERP data that exposes each one, and the usual countermeasure.

Lean Manufacturing Japanese Terms Glossary

A searchable list of common lean and Toyota Production System terms with plain English meaning and where each is used.

CNC G-Code Reference Table

A searchable table of common G-codes for milling and turning with their function, group and practical notes.

CNC M-Code Reference Table

A searchable table of common CNC M-codes for spindle, coolant, tool change, program control and subprograms, with practical notes.

Tap Drill Size Chart (UNC, UNF and Metric Coarse/Fine)

Look up the standard tap drill for common inch and metric threads, with pitch, and export the chart for the shop floor.

ISO Material Groups for Cutting Tools (P M K N S H) Reference

Map common workpiece materials to the ISO P, M, K, N, S and H groups used on carbide insert and end mill catalogs.

Fanuc Macro B System Variables Reference

A lookup table of widely used Fanuc Custom Macro B variable numbers for offsets, positions, timers and alarms.

Tap Drill Size Chart (Metric, UNC, UNF)

Searchable tap drill chart for common metric coarse, metric fine, UNC and UNF sizes with the standard drill and its diameter in mm.

Thread Pitch Chart (Metric, UNC, UNF)

Reference of thread pitch in mm, threads per inch and approximate thread depth for common metric, UNC and UNF sizes.

ISO Turning Insert Designation Code Reference

Decode the letters in an indexable insert name such as CNMG 120408: shape, clearance angle, hole type. Searchable and exportable.

NPT and BSP Pipe Thread TPI and Diameter Reference

Pipe thread sizes with TPI, pitch in mm and outside diameter for NPT and BSP (G) threads, so you stop mixing them up.

Letter Size Drill Chart A to Z with mm Equivalents

Letter drills A through Z with decimal inch and millimetre diameters, ready to search, print or export.

Sheet Metal Gauge Thickness Chart

A searchable gauge-to-thickness lookup for carbon steel, galvanized steel, stainless steel and aluminum, in inches and millimeters.

Thermoplastic Resin Processing Temperature and Shrinkage Reference

Typical processing windows, drying needs and shrinkage ranges for common injection molding resins, in a searchable table.

Cast Iron and Steel Casting Grades ASTM Reference

Look up ASTM A48, A536, A27, A216, A351, A148 and A897 casting grades with minimum tensile and yield values in ksi and MPa.

Forging Temperature Ranges by Material Reference

Searchable guide of typical hot forging start and finish temperatures in Celsius and Fahrenheit for common steels and non-ferrous alloys.

Steel Heat Treatment Processes Reference

Quick lookup of common heat treatment processes with typical temperature ranges, cooling method and what each one is used for.

Manufacturing Operating Rhythm and Meeting Cadence Reference

A lookup table of the standard meeting cadence for a manufacturing plant, from the shift start huddle to the annual strategy review, with owners, inputs and outputs.

Manufacturing Process Types and Product-Process Matrix Reference

Compare project, job shop, batch, cell, repetitive, assembly line and continuous processes by volume, variety, layout, planning approach and typical ERP setup.

Code and query generators

Thread Milling G-Code Generator

Fill in thread size, pitch, tool path radius and feed to generate a Fanuc-style helical thread milling program for an internal right-hand thread.

Fanuc G76 Threading Cycle Code Generator

Fill in thread size, pitch, depth and length and get a Fanuc style G76 two-line multi-pass threading block with comments.

Fanuc G83 Peck Drilling Cycle Code Generator

Generate a G83 deep hole peck drilling block with tool call, coolant, R plane and cancel, ready to paste into a program.

Checklists

Supply Chain Resilience Checklist

A 30-point audit across sourcing, buffers, demand visibility, ERP data quality, and disruption response, with the highest-risk items flagged as critical.

China Manufacturing Plant ERP Rollout Checklist

A rollout checklist for a new or replacement ERP in a Chinese factory, from governance and shop floor to tax and hypercare.

5S Audit Checklist

A 30-point 5S audit covering Sort, Set in Order, Shine, Standardize and Sustain, with scoring you can export.

Gemba Walk Checklist

A 28-point gemba walk checklist covering safety, quality, flow, standard work and people, with an exportable result.

Lathe Chatter Troubleshooting Checklist

A step-by-step checklist to find and fix chatter, grouped by workholding, tooling, cutting parameters and machine condition.

Internal Turning and Boring Bar Setup Checklist

A practical checklist for setting up boring bars on CNC lathes, to cut chatter, scrap and crashed tools.

Plant Manager First 90 Days Checklist

A structured list for new plant managers covering safety, people, customers, performance data, systems and early priorities.

Plant Expansion Project Readiness Checklist

A gate review checklist covering demand case, capacity, site and utilities, permits, workforce and ERP readiness before approving a plant or line expansion.