Professional Documents
Culture Documents
Basic Kaizen Tools
Basic Kaizen Tools
BASIC KAIZEN
KAIZEN
TOOLS
TOOLS
1.1. TARGET
TARGETPROGRESS
PROGRESSREPORT
REPORT
2.2. STANDARDIZED
STANDARDIZEDWORK
WORKSHEET
SHEET
3.3. TIME
TIMEOBSERVATION
OBSERVATIONSHEET
SHEET
4.4. CYCLE
CYCLETIME
TIME//TAKT
TAKTTIME
TIMEBAR
BARCHART
CHART
5.5. YAMAZUMI
YAMAZUMI(STACK)
(STACK)CHART
CHART
6.6. STANDARDIZED
STANDARDIZEDWORK
WORKCOMBINATION
COMBINATIONSHEET
SHEET
7.7. CAPACITY
CAPACITYSHEET
SHEET
8.8. KAIZEN
KAIZENPROPOSAL
PROPOSALSHEET
SHEET
9.9. KAIZEN
KAIZENNEWSPAPER
NEWSPAPER
Using
Using the
the Basic
Basic Kaizen
Kaizen
Tools
Tools
3
1 2 3
1 2
4
4 5 6
5 6
If equipment seems to lack in
If equipment seems to lack in Note long times on Combination
capacity, use Capacity Sheet to Note long times on Combination Try out ideas for kaizen
capacity, use Capacity Sheet to Sheet, there are opportunities for Try out ideas for kaizen
define problems. Sheet, there are opportunities for immediately, verify results.
define problems. Kaizen. immediately, verify results.
Fill out Standardized Work Kaizen. Prepare Kaizen Proposal Sheets
Fill out Standardized Work Continue to observe site, note Prepare Kaizen Proposal Sheets
Combination Sheet with best Continue to observe site, note for effective kaizen ideas.
Combination Sheet with best problems on Kaizen Newspaper for effective kaizen ideas.
times. problems on Kaizen Newspaper
times.
7
7
CATEGORY CURRENT TARGET DAY 1 DAY 2 DAY 3 DAY 4 FINAL RESULT % CHANGE
INVENTORY
WALKING DISTANCE
CREW SIZE
PRODUCTIVITY
REMARKS:
STANDARDIZED WORK SHEET DATE: _____/____/____
Process: __________________________ Approvals:
Part # ____________________________ Scope of
FROM:
Operation
Part Name: ________________________ TO:
SYMBOLS Quality Safety Standard Work Total Pcs of Std Takt Cycle Operators
NOTE: Takt Time, Work Sequence (same as numbers in “Step” column on BASIC
Check Precaution In Process Work in Process Time Time this op/line total
Combination Sheet), and numbers of Standard Work in Process must be
known to define Standardized Work. Identify all safety concerns, points where DATA
quality must be verified (go/no-go) and numbers of pieces of standard work in 1/
sec.
process using the symbols to the right.
Page _____ of _____
TIME OBSERVATION SHEET
Date / Time: ___/____/____/_________________:________
Line / Process: __________________________________________________
Observed by: _____________________________________
10
11
12
13
14
15
1 2 3 4 5 6 7 8 9
Process
Cycle Time / Takt Time Bar
Chart (with Graphing
Cycle Time / Takt Time Bar Chart
Feature)
1.2
1 T/T
0.8
Cycle Time
0.6
0.4
0.2
0
1 2 3 4 5 6 7
Before
After Process
Yamazumi (Stack) Chart
Yamazumi (Stack) Chart (Blank Chart)
Cycle Time
1 2 3 4 5 6 7 8 9
Process
Yamazumi (Stack) Chart
(with Graphing Feature)
Yamazumi (Stack) Chart
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6
1
0.8
Cycle Time
T/T
0.6
0.4
0.2
0
1 2 3 4 5 6 7
Process
Operator _____ of _____
STANDARDIZED WORK
Line: ____________________________ COMBINATION SHEET MANUAL:
Date: ______/______/_______ Quota / Shift: ____________
AUTO:
Process: _________________________
Section: __________________ Takt Time: ______________ sec. WALKING:
Waiting
Totals
Page ____ of ____
New / Revised as of (date): ___/___/___
Authorizations:
CAPACITY SHEET Current Output
Part No. Line pieces
Per Day
Max Output Workers
Part Name pieces
per Day Needed
Times: Manual
Machine Base Times Tools
Step Description Capacity Remarks Automatic
ID Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/Piece Walking
Subtotal NOTE
Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.
Total
KAIZEN PROPOSAL SHEET
Location Objective Date Operator
Before After
Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)
KAIZEN NEWSPAPER
TEAM: __________________________________ DATE: _______/_______/_______/___________
改
In recognition of your earnest efforts to learn
and practice kaizen during the [XXX] Kaizen
Workshop held at [XXX] factory during the
week of [Date], you have been granted this
license to practice kaizen daily in accordance