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BASIC KAIZEN TOOLS

1. 2. 3. 4. 5. 6. 7. 8. 9. TARGET PROGRESS REPORT STANDARDIZED WORK SHEET TIME OBSERVATION SHEET CYCLE TIME / TAKT TIME BAR CHART YAMAZUMI (STACK) CHART STANDARDIZED WORK COMBINATION SHEET CAPACITY SHEET KAIZEN PROPOSAL SHEET KAIZEN NEWSPAPER

Using the Basic Kaizen Tools


1 2
3

Calculate Takt Time. Identify problems. Set targets and enter on Target Progress Report Plan & initiate Kaizen Workshop.

Observe site. Identify Process. Prepare Standardized Work Sheet

Pair up 2 for each process. One times w/ stopwatch, other jots down times. Find best times. Verify if Cycle Time meets Takt Time.

If equipment seems to lack in capacity, use Capacity Sheet to define problems. Fill out Standardized Work Combination Sheet with best times.

Note long times on Combination Sheet, there are opportunities for Kaizen. Continue to observe site, note problems on Kaizen Newspaper

Try out ideas for kaizen immediately, verify results. Prepare Kaizen Proposal Sheets for effective kaizen ideas.

Update Kaizen newspaper. Update Target Progress Report.

Kaizen EVERY DAY!!.

TARGET PROGRESS REPORT


Department / Section / Site Date: ___/____/____/____/__________ Takt Time: _______________________

CATEGORY SPACE (sq. ft.) INVENTORY WALKING DISTANCE MATERIAL TRAVEL DISTANCE LEAD TIME (sec.) CYCLE TIME (sec.) OUTPUT (units / day) CREW SIZE PRODUCTIVITY CHANGEOVER TIME (sec.)

CURRENT

TARGET

DAY 1

DAY 2

DAY 3

DAY 4

FINAL RESULT

% CHANGE

REMARKS:

Process: __________________________ Part # ____________________________ Part Name: ________________________


Scope of Operation FROM: TO:

STANDARDIZED WORK SHEET

DATE: _____/____/____ Approvals:

NOTE: Takt Time, Work Sequence (same as numbers in Step column on Combination Sheet), and numbers of Standard Work in Process must be known to define Standardized Work. Identify all safety concerns, points where quality must be verified (go/no-go) and numbers of pieces of standard work in process using the symbols to the right.

SYMBOLS

Quality Check

Safety Precaution

Standard Work In Process

BASIC DATA

Total Pcs of Std Work in Process

Takt
Time sec.

Cycle
Time

Operators this op/line total

1/

TIME OBSERVATION SHEET


Line / Process: __________________________________________________

Page _____ of _____

Date / Time: ___/____/____/_________________:________ Observed by: _____________________________________


11 12 13 14 15

# 1

Step

1
0

10

Best Time

Observations (changeover time)

2
3 4 5 6 7 8 9 10 11 12 13 14 15 Complete Cycle Time

Time / Takt Time Bar Chart (Blank Chart) Cycle Cycle Time / Takt Time Bar Chart

Cycle Time
1 2 3 4 9 5 6 7 8

Process

Cycle Time / Takt Time Bar Chart (with Graphing Cycle Time / Takt Time Bar Chart Feature)
1.2 1 0.8 0.6 0.4 0.2 0 Before After
T/T
Cycle Time

4 Process

Yamazumi (Stack) Chart (Blank Chart) Yamazumi (Stack) Chart

Cycle Time
1 2 3 4 9 5 6 7 8

Process

Yamazumi (Stack) Chart (with Graphing Feature) Yamazumi (Stack) Chart


Task 1 1 0.8 0.6 0.4 0.2 0 1 2 3 4 Process 5 6 7 Task 2 Task 3 Task 4 Task 5 Task 6

Cycle Time

T/T

Operator _____ of _____

Line: ____________________________
Process: _________________________

STANDARDIZED WORK COMBINATION SHEET


Time 5 10 15 20 25

Date: ______/______/_______ Section: __________________


TIME (unit: 1 sec.) 30 35 40 45 50

Quota / Shift: ____________ Takt Time: ______________ sec.


55 60 65 70 75 80

MANUAL: AUTO: WALKING:

Step

Description

Man Auto Walk

85

90

Waiting

Totals

Page ____ of ____ New / Revised as of (date): ___/___/___


Authorizations:
Current Output Per Day Workers Needed
Times: Manual Automatic Walking

Step

Description

Machine ID

CAPACITY SHEETBase Times


Walking Time Manual Time

Part No. Part Name

Line Max Output per Day Tools Pieces/Run Change Time Time/Piece Capacity pieces

pieces

Auto Run Time Completion Time

Remarks

Subtotal Total

NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in Remarks column.

KAIZEN PROPOSAL SHEET


Location Objective
Date Operator

Before

After

Problem

Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

KAIZEN NEWSPAPER
TEAM: __________________________________
No. PROBLEM WHO

DATE: _______/_______/_______/___________
BY WHEN CHECK

Kaizen License
[Name of Recipient]


John Doe Plant Manager

In recognition of your earnest efforts to learn and practice kaizen during the [XXX] Kaizen Workshop held at [XXX] factory during the week of [Date], you have been granted this license to practice kaizen daily in accordance with the principles of Just in Time, Quality in Station, Production leveling, and Production Preparation.

John Doe Kaizen Promotion Leader

John Doe Consultant

Expiration Date: [1 year from date of issuance]