BASIC KAIZEN BASIC KAIZEN TOOLS TOOLS

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

Using the Basic Using the Basic Kaizen Tools Kaizen Tools
1 1 2 3 2 3

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

Observe site. Observe site. Identify Process. Identify Process. Prepare Standardized Prepare Standardized Work Sheet Work Sheet

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

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

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

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

Update Kaizen newspaper. Update Kaizen newspaper. Update Target Progress Report. Update Target Progress Report.

Kaizen EVERY DAY!!. 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 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Step

1
0

10

Best Time

Observations (changeover time)

Complete Cycle Time

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

Cycle Time
1 2 3 4 5 6 7 8 9

Process

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

Cycle Time
1 2 3 4 5 6 7 8 9

Process

Operator _____ of _____ Line: ____________________________ Process: _________________________

MANUAL: AUTO:

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

WALKING:

Step

Description

Man Auto Walk

85

90

Waiting

Totals

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

Authorizations:

Page ____ of ____

Current Output Per Day Workers Needed
Times: Manual Automatic Walking

CAPACITY SHEET
Step Description Machine ID Walking Time Base Times 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