Kaizen - Report CELL LAYOUT

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 :
YEAR MONTH NO.
OPERATOR WENT TO TAKE DIE FROM DIE MAINTENANCE. DIE RACK PROVIDED ON CELL.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.
THERE WAS NO SUFFICIENT TIME FOR ANTIRUST CURING CAUSING ANTIRUST

STAND PROVIDED TO GET SUFFICIENT TIME FOR ANTIRUST CURING.
SPILLAGE ON PART.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.
TWO PRESSES REQUIRED FOR NOTCHING AND BENDING OPERATION. ONE PRESS ELIMINATED USING BENDING AND NOTCHING TOOL IN ONE DIE.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.
THERE WAS NO PROVISION FOR MARKING THE PART ON TABLE. CYLINDER PROVIDED WITH MARKIER FOR MARKING THE PART ON TABLE.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.
WORK WAS NOT IN STANDARD ALSO THERE IS INCONVEINIENCE TO TEAM ROTATING TRAY PROVIDED FOR STANDARD WORK WHICH IS CONVENIENCE
MEMBER. TO TEAM MEMBER.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.

Q
P


F : PED : 025 - 01; 03 Aug 13
PLANT DEPTT DATE
KAIZEN REPORT
1. KAIZEN THEME :
YEAR MONTH NO.
N/A

Q
P


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 process.May
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
process.May 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 understand.All 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

Kaizen - Report CELL LAYOUT

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Kaizen - Report CELL LAYOUT

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PLANT DEPTT DATE

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

MUDA OF WALKING IN CURRENT LAYOUT MUDA ELIMINATED BY CELL LAYOUT CHANGE

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

THERE WAS NO SUFFICIENT TIME FOR ANTIRUST CURING CAUSING ANTIRUST

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

SUGGESTED BY SIGN. APPROVED BY SIGN. IMPLEMENTED BY SIGN. KAIZEN DETAIL

YEAR MONTH NO.

3. PHOTOGRAPH (BEFORE KAIZEN) 4. PHOTOGRAPH (AFTER KAIZEN)

WHEN FOUND ? WHEN IMPLEMENTED ?

7. KAIZEN EVALUATION MEASURABLE BENEFITS HORIZONTAL DEPLOYMENT

Evaluation by Assessing Team C

Cost of Kaizen : Payback period :

Prevents frequently occuring

Quality level improved < 20% Reduction of problem by >20 %

Productivity level improved by

Small improvements in work Good improvements in work

Drastic Improvements in work

Some aspects difficult to