Supplier Development

Kaizen Implementation Kit

Rev. 3
 Kaizen Implementation Kit Summary
Kaizen Event Description
Product Quantity Analysis Product Family
Process Matrix Identification Tools
Value Stream Map
Takt Time
Time Observations
Operations and Operator Balance Charts
Standard Work Combination Sheet Analysis and
Standard Work Sheet Improvement Tools
Capacity Study
Setup Reduction
Spaghetti Chart
5S Audit
Machine Down Time
Target Matrix
Kaizen Newspaper Measures
Kaizen Principles
Daily Outbrief
Inbrief Presentation Communication
Outbrief Presentation
 KAIZEN EVENT DESCRIPTION
General overview of the Supplier
Development process of conducting a
Kaizen event. It includes an overview
and description of the pre-event, the Kaizen Event
kaizen event week and the post event Description Instructions
follow up.

Please read the Kaizen Event

Description before utilizing the Kaizen
Kit tools and templates. Kaizen Event
Description
 PRODUCT QUANTITY ANALYSIS

Analyzes the relationship between

products and quantity (production
output). This will help evaluate the mix
of products being produced.
PQ Analysis PQ Analysis
Instructions Template

PROCESS MATRIX
A Process Matrix will highlight which
parts should be processed together
in a cell and which parts should be
reprocessed in order to match the
flow of other parts. Process Matrix Process Matrix
Instructions Template
 VALUE STREAM MAP
Defines the flow of materials
and information required to
bring a product or service to a
consumer and identify where
there is waste in the process Manufacturing Business VSM Template
and help find ways to eliminate VSM Instructions
Process VSM Instructions
that waste.

TAKT TIME
Takt time is the pace of production
required to meet customer demand.
Since takt time is defined by the
customer, it becomes a very important
number in a lean environment and TAKT Time TAKT Time
drives all floor shop decisions Instructions Template
 TIME OBSERVATION
Calculates the standard time to
complete each operation in a process.
This time observation is then used to
balance the line to meet Takt time.
Time Time
Observation Templat
Observation Instructions

OPERATIONS BALANCE CHART

Identifies the capacity of operations,

opportunities for one piece flow, and
the location for placement of standard
work in process (SWIP) to maintain Operations Operations
part flow. Identifies operations that
Balance Chart Instructions
may be combined and operations that Balance Chart Templat
do not meet TAKT time.
STANDARD WORK COMBINATION SHEET

A form that visually charts the

information from a time sheet
observation. It provides a guide for the
operator in the manufacturing of a part. Standard Work Standard Work
It is used to illustrate the best Combination Sheet
Combination
Instruct Sheet Tem
combination of worker and machine.

STANDARD WORK SHEET

Graphically shows the pre-determined
sequence of tasks for the best way to
get the job done in the amount of time
available (within takt time) while
ensuring the job is done right the first Standard Work Standard Work
time, every time. Sheet InstructionsSheet Template
 CAPACITY STUDY
Identifies process capacity limitations.
This provides the baseline for
improvement, primarily through waste
reduction. Capacity Study Capacity Study
Instructions Template

SET UP REDUCTION
Identifies waste, value add and tasks
which may be done simultaneously
and/or while the machine/process is in
operation. Set Up Set Up
Reduction Instructions
Reduction Template
 SPAGHETTI CHART
Graphically illustrates the flow of
product through the factory in an effort
to highlight waste in the form of excess
travel distance.
Spaghetti Chart Spaghetti Chart
Instructions Template

5S AUDIT
Calculates the 5S score for
manufacturing and office environments.
Identifies the areas of improvement.

5S Instructions 5S Template
 MACHINE DOWNTIME
Identifies reasons and
frequency of machine
downtime and use this data to
find corrective actions Machine Machine Machine
Downtime Example
Downtime Instructions Downtime Template
 TARGET MATRIX
Identifies specific improvement targets
during pre-Kaizen activities and track
progress toward meeting the targets
during the Kaizen event.
Target Matrix Target Matrix
Instructions Template

KAIZEN NEWSPAPER
Captures all the action items during a
Kaizen event, assigns a person
responsible to complete the open
action item and sets target dates.
Newspaper Newspaper
Instructions Template
 KAIZEN PRINCIPLES
Used to assess a plant / factory /
company on its adherence to
Kaizen Principles that are key to Kaizen Principles Kaizen Principles
Lean implementation. Instructions Template

Logistic Machine and Layout Principles

Principles Template
Tooling Principles Template Template
 DAILY OUTBRIEF
Shares daily successes and challenges
with other groups and management
during the pre-event and event.

Daily Outbrief
Instructions

INBRIEF PRESENTATION
Informs management, the
Sensei and new team
members of the opportunities
identified during pre-event Kaizen Inbrief Kaizen Inbrief PPT Small File
week and to establish the Instructions Template Size
event week goals.
 OUTBRIEF PRESENTATION
Summarizes kaizen performance
improvements achieved during
event week and to identify future
actions needed to fully realize
event goals. Kaizen Outbrief Kaizen Outbrief PPT Small File
Instructions Template Size