Ability check sheet: Leadership (development of staffs) 1/10

Plant: Section:　　　　　　　　Job title:　　　　　Years of employment:　　　　　　Name:　 Missionary:

Do not know Know, but no experience Have experiences. Can instruct. Can make the system. Evaluation
Level 3 　　　　　　　　　　 Level 4 　　　　　　　　　　 　 Level 5　　　　　　　　　
Sort No. Check point Purpose Level 1 Level 2
(TL) Initiate missionary (SL) Apprentice missionary (excellent SL) Missionary
Self Judge
Do not instruct Find out necessary
Instruct associates (OJT) Instruct associates about knowledge/skills at each work site
Formalize necessary tacit
１－１ Work instruction To hand down skills to associates associates acout working
following manuals.
feeling or knack work which and make a system for better understanding (feeling, 4
methods. is not indicated on manuals. training. knack).
Follow up the plans and
Development of skilled To develop associates (operators) Do not know what the Follow up the plans and
１－２
associates according to plans skilled associate is.
Just know (no experience). Make plans for the training.
deal with troubles.
instruct associates how to 2
deal with troubles.
Follow up the plans and
To raise the level of associates Do not know the contents of Know about it, but never Follow up the plans and
１－３ Education, qualifying plan
following training plans education and qualification. use.
Make plans for the training.
deal with troubles.
instruct associates how to 1
deal with troubles.
Do not have unified Make manuals to receive
To improve the work learning level of Follow the training, using
１－４ Training of new associates
new associates
Do not train new associates. Just know (no experience). instruction methods, but can
unified instruction cards.
new associates on each 1
Leadership instruct new associates. work site.
Instruct associates about
To have knowledge about Do not know about Know names of Know about roles and Know important points of
(Developmen １－５ Knowledge about products
manufacturing products products. products(parts). functions of products. product quality.
important points of product 2
t of staffs) quality.

Principle of job site & actual To check actual things at the actual Know the meaning, but Find out causes at the Seek real causes and take
１－６
article work site and see the fact
Do not know the meaning.
never use. actual site. right action.
Make know-how manuals. 2
Know that information
Share necessary Make a system for
sharing is important Hold a morning meeting
１－７ Information sharing To communicate with people well Do not know the importance.
(Report, Inform, Consult, and share information.
information with related information sharing (e.g. 2
sections. morning meeting).
etc.).
To learn how to solve problems and Do not know about QC Know about it, but cannot Instruct associates how to
１－８ QC circle activity
importance of teamwork circle activity. conduct for real.
Be a leader of QC circle.
solve problems.
Make plans for activation. 2
Instruct associates Educate associates and
Do not know the Explain associates about Promote and fix 5S
１－９ 5-S activity To understand basic works
meaning. each activity.
depending on each make training materials for
activity (e.g. 5S patrol) 2
situation. 5S.
Instruct associates about
Know visialized items and Implement the
１－１０ Visualization To visualize the current situation Do not know. Know.
the purpose. visualization.
the importance of 2
visualization.
Promote specific
All associates participate in Make plans to improve
１－１１
KAIZEN activities.
To make work sites active Do not know. Know. activities (e.g. Post-it
the participating rate.
Show specific activities. 2
activity).
Set individual targets
See individual targets Gain cooperations from
considering work sites'
１－１２ Target control To achieve targets Do not know the targets. Know the targets.
targets and promote
and give associates related sections and 2
some advice. achieve targets.
activities.

Average 2.0

Comment (strong points) Comment (weak points)

1)Ability to make Work instruction 1)Never use the PDCA for development of associates
2)Know the name of the parts 2)Individual target on line never made
 Ability check sheet: Quality 2/10
Plant: Section:　　　　　　　　Job title:　　　　　Years of employment:　　　　　　Name:　 Missionary:
Do not know Know, but no experience Have experiences. Can instruct. Can make the system. Evaluation
Level 3 　　　　　　　　　　 Level 4 　　　　　　　　　　 　 Level 5　　　　　　　　　
Sort No. Check point Purpose Level 1 Level 2
(TL) Initiate missionary (SL) Apprentice missionary (excellent SL) Missionary
Self Judge
Prepare check sheets which
Previous preparation for new To understand changing and important Find out problematic Review manuals and
２－１
products points of products
Do not know. Know, but no experience
points on the trial. maintain jigs.
check the workmanship 2
before L/O.
olumC
nS Stratify defects and Conduct
To seek out causes of defects and Make problem solving
２－２ Countermeasures for defects
conduct countermeasures Colum Do not know. Know. promote countermeasures
manuals. 3
nT countermeasures. involving related sections.
Do not know about the Grasp the tendency and
To prevent occurrence of defects, control charts (center point Calculate the control limit Take appropriate actions for Instruct associates about
２－３ Control chart
using control charts control, control limit line, line and Ｃｐｋ.　
troubles on the control deal with the matter
the control charts. 2
charts. beforehand.
etc.)
Check the accuracy at
Know about daily check
Make necessary check regular intervals Instruct associates about
２－４ Measuring tool control To assure accuracy of the tools Do not know. and accuracy assuring
manuals. (including requests ot gauge R&R.　 3
Quality label.
other sections).
Make manuals receiving Make working manuals Show problematic points Make the know-how clear
２－５ Working manual To unify working procedures Do not make manuals.
advice. and instruct associates. on manuals. and teach skills. 3
Judge OK/NG of
Understand simple Assemble products Teach associates how to
２－６ Reading of product drawings To make products following drawings Do not know. products from the 2
0

drawings. seeing the drawing. read drawings.

drawings.
Explain changing points Check changing points Make a system that
２－７ Design change/ Process change To stratify new and old products Do not know. Know.
to associates. and judge OK/NG. prevents re-occurrence. 3

To share information each other by Use 5M１E changing Instruct how to deal with Make a system that
２－８ Control of 5M１E changing points　
visualization
Do not know. Know.
control board. changing points. controls changing points. 2

To understand a definition and control Know the meanings of Know about the relevant Know the designated and
２－９ Critical control designated products
methods
Do not know the purpose. Know the purpose.
indications. products. releasing rule. 2

Do not know the control Deal with defects Suggest specific ideas for
２－１０ POKAYOKE control　 To assure the accuracy
rule.
Know the control rule. Make check sheets.
appropriately. necessary POKAYOKE. 3
Show assurance items in Evaluate the level Promote assurance level-up
Do not know about SQA own section （reflect them
２－１１ SQA (PQA)　 To raise the assurance level
(PQA).
Know about SQA (PQA). on manuals, instruct
(occurrence/non- activity (KAIZEN of 3
detection). POKAYOKE/work).
associates).

Average 2.5

Comment (strong points) Comment (weak points)

1) cannot assemble the product by drawing
1)Can use seven qc tools for resolving problems 2) Never made SQA matrix
2)can make working manual
 Ability check sheet: Cost (workability) 3/10
Plant: Section:　　　　　　　　Job title:　　　　　Years of employment:　　　　　　Name:　 Missionary:
Do not know Know, but no experience Have experiences. Can instruct. Can make the system. Evaluation
Level 3 　　　　　　　　　　 Level 4 　　　　　　　　　　 　 Level 5　　　　　　　　　
Sort No. Check point Purpose Level 1 Level 2
(TL) Initiate missionary (SL) Apprentice missionary (excellent SL) Missionary
Self Judge
0

Analyse differences
Colum
nS
Colum
nT

Control the production Suggest KAIZEN ideas to

３－１ Man-hour decreasing activity To improve the workability Do not know. Know.
amount.
between the plan and
achieve targets. 3
performance.
Instruct associates about
Suggest problems for line Make one by one
３－２ One by one production To visualize problematic points Do not know. Know. one by one production
making. production process. 2
method.
Instruct associates about
To make workloads on associates
３－３ Efficiency of formation
equal
Do not know. Know (can calculate). Make element charts. Even out the elements. the practical method and 2
Cost training.
Promote KAIZEN from
Make three standard
３－４ Standard work To find out troubles Do not know. Know. Make standards.
sheets
the three standard 1
(Workability) sheets.
Explain the sort and Improve MUDA Instruct associates how
３－５ 7 MUDA To continue KAIZEN activities Do not know. Know.
definition of each MUDA. specifically. to decrease MUDA. 2

Analyse downtime Suggest KAIZEN ideas to

３－６ Improvement of operation rati To improve the workability Do not know. Know. Calcurate operation ratio.
causes. achieve targets. 4
Explain average work Instruct associates about
３－７ Working speed To make working loads equal Do not know. Know the concept.
speed "100".
Check working speed.
working speed. 1

Know how to use the Instruct associates about

３－８ Standard man-hour To improve the workability Do not know. Know. Know the setting rule.
standard man-hour. the process control. 1

Know how to use Instruct associates about Promote KAIZEN using

３－９ Use of ANDON To find out and deal with troubles quickl Do not know. Know.
ANDON. the use of ANDON. ANDON. 1
Understand factors which
Assign associates
３－１０ Plan for man-power To arrange associates without MUDA Do not know. Know. Calculate man-power. affect manpower
appropriately. 1
planning.

Average 1.8

Comment (strong points) Comment (weak points)

1) Hrly production report displayed at shop floor for finding gaps 1)One by one not followed on line
2)line balancing not done to equal the work load
3)No work as per process sheet/work instruction
4)Cycle time standard not available
 Ability check sheet: Delivery 4/10
Plant: Section:　　　　　　　　Job title:　　　　　Years of employment:　　　　　　Name:　 Missionary:
Do not know Know, but no experience Have experiences. Can instruct. Can make the system. Evaluation
Level 3 　　　　　　　　　　 Level 4 　　　　　　　　　　 　 Level 5　　　　　　　　　
Sort No. Check point Purpose Level 1 Level 2
(TL) Initiate missionary (SL) Apprentice missionary (excellent SL) Missionary
Self Judge
Deal with abnormal Instruct associates about
To see production delay/ progress by Set target amount per
４－１ Production amount check shee
the hour
Do not know. Know.
hour.
phenomenon the practical method and 3
appropriately. traning.

Know about the sorts and Explain flow of products Make a flow chart of Instruct associates about
４－２ KANBAN To prevent over-production Do not know.
function of KANBAN. and information. products and information. the practical method. 1

Know about the first-in, Improve the first-in, first- Know about fill-up Implement fill-up
４－３ Stock control To promote first-in and first-out Do not know.
first-out system. out system. production system. production. 2
Delivery
Know about sorts of Suggest KAIZEN ideas Instruct associates about
４－４ Logistics To make transportation more effective Do not know.
transportation.
Make purchase lists.
for logistics. KAIZEN of logistics. 1

To know production delay/ progress on Control the delay and Deal with the changes of Make trouble shooting
４－５ Production progress control
the day
Do not know. Know.
progress. production amount. manuals. 3

Instruct associates about

４－６ Lead time To reduce detention time Do not know. Know. See the leadtime. Improve the lead time.
KAIZEN of lead time. 1

Average 1.8

Comment (strong point) Comment (weak points)

1)Hrly production amount monitored 1)Do not know kanban
2)Know the first in first out 2)Donot know the effective system of logistics
3)No data of lead time
 Ability check sheet: Safety 5/10
Plant:
　 Section:　　　　　　　　Job title:　　　　　Years of employment:　　　　　　Name:　 Missionary:
Do not know Know, but no experience Have experiences. Can instruct. Can make the system. Evaluation
Level 3 　　　　　　　　　　 Level 4 　　　　　　　　　　 　 Level 5　　　　　　　　　
Sort No. Check point Purpose Level 1 Level 2
(TL) Initiate missionary (SL) Apprentice missionary (excellent SL) Missionary
Self Judge

Instruct associates about Instruct associates about

Know about safety
５－１ Safety device To understand the sorts and fuctions Do not know.
devices at the work site.
the functions and check Check safety devices. the standard of safety 2
methods. devices (DAS).

Instruct associates about

５－２ 3S activity To promote safe work Do not know. Know. Explain meanings of 3S.
3S activity.
Make a system to fix 3S. 2

Know about Heinrich's Suggest countermeasure Promote near-miss

５－３ Near-miss To make un-safe places clear Do not know. Know the word.
law. for near-miss. prevention activity. 3
Safety
Know about MSDS Instruct associates about
５－４ Handling of dangerous objectsTo keep the controlling condition Do not know. Know. Know the control rules.
system the control method. 1
Know about sorts and Indicate in the necessary
Understand the
５－５ Protective clothes To keep work safe Do not know.
importance.
roles of protective protective clothes for Make a system for fixing. 2
clothes. work.
Know about M/C safety
Make a system for safety
５－６ Safety check for new M/C To improve un-safe places Do not know. Know. standard (e.g. safety Check safety of M/C.
check. 2
gap).
Know about cooperative
Make manuals for
５－７ Safety work To prevent occurrence of troubles Do not know. Know. work and handling of
cooperative work.
Make a system for fixing. 2
heavy loads.
Make a system for boosting
Instruct associates about Deploy accident news to
５－８ Educational activity To boost awareness of safety Do not know. Know.
safety. other sections.
associates' awareness for 3
safety.

Average 2.1

Comment (strong points) Comment (weak points)

1)Know about heinrich law 1)No explanation given for meaning of 3S
2)Training provided for awareness of safety 2)Do not know the handling of dangerous objects