PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
MUDA OF WALKING IN CURRENT LAYOUT MUDA ELIMINATED BY CELL LAYOUT CHANGE
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
OPERATOR WENT TO TAKE DIE FROM DIE MAINTENANCE. DIE RACK PROVIDED ON CELL.
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
THERE WAS NO SUFFICIENT TIME FOR ANTIRUST CURING CAUSING ANTIRUST
STAND PROVIDED TO GET SUFFICIENT TIME FOR ANTIRUST CURING.
SPILLAGE ON PART.
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
TWO PRESSES REQUIRED FOR NOTCHING AND BENDING OPERATION. ONE PRESS ELIMINATED USING BENDING AND NOTCHING TOOL IN ONE DIE.
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
THERE WAS NO PROVISION FOR MARKING THE PART ON TABLE. CYLINDER PROVIDED WITH MARKIER FOR MARKING THE PART ON TABLE.
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
WORK WAS NOT IN STANDARD ALSO THERE IS INCONVEINIENCE TO TEAM ROTATING TRAY PROVIDED FOR STANDARD WORK WHICH IS CONVENIENCE
MEMBER. TO TEAM MEMBER.
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL
YEAR MONTH NO.
3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)
N/A
5. BEFORE KAIZEN (PROBLEM) PLEASE GIVE BRIEF DESCRIPTION 6. AFTER KAIZEN (HOW IMPROVED) PLEASE GIVE BRIEF DESCRIPTION
WHAT IS THE PROBLEM ? WHERE FOUND ? WHAT IS THE COUNTERMEASURE ? WHERE IMPLEMENTED ?
WHEN FOUND ? WHEN IMPLEMENTED ?
7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT
CATEGORY BEFORE AFTER SAVING AREA RESP TGT DATE COMP. DATE
Area od Improvement S Q P C M S
Q
Please Tick in resp. Column
P
Evaluation by Assessing Team C
( As per Evaluation Criteria ) M
Cost of Kaizen : Payback period :
F : PED : 025 - 01; 03 Aug 13
KAIZEN EVALUATION CRITE
Category Kaizen Points
A Score 1 ~ 15 16 ~ 30
Prevents frequently occuring
Prevents low frequency & low
Safety severity injuries
injuries of low severity that
require First aid etc.
Quality level improved < 20% Reduction of problem by >20 %
Quality from current condition. May not in the current [Link]
sustain for long term. sustain for long term.
Productivity level improved by
Productivity level improved <
>20% in the current
Productivity 20% from current condition. May
[Link] sustain for long
not sustain for long term.
term.
75
Monthly Cost Saving < Rs. 5000. Monthly Cost Saving > Rs. 5000.
Cost May not sustain for long term. May sustain for long term
Small improvements in work Good improvements in work
Morale environment. Area needs further environment. May sustain for
improvements long term
Drastic Improvements in work
Small improvements in work
environment i.e Natural Lighting,
EMS place w.r.t Natural Lighting,
Ventilation. Reduces Water / Oil
ventilation etc.
spillage, Bad odour, fumes etc.
B Score 1 2
Some aspects difficult to
Quality of
5 Totally difficult to understand [Link] details as per
Kaizen Sheet format not filled
Partially applicable for current Fully applicable for current Line /
Applicability 5 Line / Product. Implementation Product only. Implementation
done done
Existing idea & moderate New idea but small amount of
Originality 5 imagination. creativity & imagination.
Partial support taken from other
Implementation done with major
Efforts 5 support from outside
Deptt. No survey / Trial & error
involved.
Investment 5 Kaizen cost > 20,000 Kaizen cost > 15,000
VALUATION CRITERIA
Kaizen Points
31 ~ 45 46 ~ 60 61 ~ 75
Prevents frequently occuring Prevents severe injury that may Prevents fatal accidents &
injuries of moderate severity that cause permanent disability or property damage of severe
lead to company loss (Rs) reduced capability nature
Reduction of problem by >75%.
Reduction of problem by >50%. 100% Elimination of problem i.e
Prevention of defects to next
Standardization done to sustain. Poka Yoke in Occurance.
process
Productivity level improved by
Productivity level improved by Productivity level improved >
>50%. Standardization done to
>75% from current condition. 100% from the current condition.
sustain.
Monthly Cost Saving > Rs.
Monthly Cost Saving > Rs. Monthly Cost Saving> Rs.
10,000. Standardization done to
15,000. 20,000
sustain
Reduction in painful working
Elimination of painful working Work environment ergonomically
condition. Standardization done
condition. good. Bench mark for others
to sutain
Reduces generation of noise,
Avoids non compliance raised
Hazardous waste or air & water Avoids legal non compliance
by External Auditor / Customer
consumption etc.
3 4 5
Some aspects difficult to
Self explanatory. All details as Self Explanatory.100%
understand.100% conformance
per format not filled conformance to format.
to format
Partially applicable to multiple 100% applicable to multiple 100% Applicable to multiple
Products/Processes with No / Products/Processes with major Products/Processes with no /
little change. changes. little change.
New Idea and good amount
Existing idea but good amount of New idea with fair amount of
amount of innovation &
creativity creativity
conceptulization
Partial support taken from other
100% Implementation by self. 100% implementation by self.
Deptt.. Trial & error / survey
No trial & error involved Heavy trial & error involved
involved.
Kaizen cost > 10,000 Kaizen cost > 5,000 Kaizen cost < 5,000
