BASIC KAIZEN TOOLS 1. 2. 3. 4. 5. 6. 7. 8. 9. TARGET PROGRESS REPORT STANDARDIZED WORK SHEET TIME OBSERVATION SHEET CYCLE TIME / TAKT TIME BAR CHART YAMAZUMI (STACK) CHART STANDARDIZED WORK COMBINATION SHEET CAPACITY SHEET KAIZEN PROPOSAL SHEET KAIZEN NEWSPAPER Using the Basic Kaizen Tools 1 3 2 Calculate Takt Time. Identify problems. Set targets and enter on Target Progress Report Plan & initiate Kaizen Workshop. 4 Observe site. Identify Process. Prepare Standardized Work Sheet 5 If equipment seems to lack in capacity, use Capacity Sheet to define problems. Fill out Standardized Work Combination Sheet with best times. 6 Note long times on Combination Sheet, there are opportunities for Kaizen. Continue to observe site, note problems on Kaizen Newspaper 7 Update Kaizen newspaper. Update Target Progress Report. Pair up 2 for each process. One times w/ stopwatch, other jots down times. Find best times. Verify if Cycle Time meets Takt Time. Try out ideas for kaizen immediately, verify results. Prepare Kaizen Proposal Sheets for effective kaizen ideas. 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.) REMARKS: CURRENT TARGET DAY 1 DAY 2 DAY 3 DAY 4 FINAL RESULT % CHANGE Process: __________________________ Part # ____________________________ Part Name: ________________________ DATE: _____/____/____ STANDARDIZED WORK SHEET Scope of Operation Approvals: FROM: TO: 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 Safety Standard Work Check Precaution In Process BASIC DATA Total Pcs of Std Takt Cycle Operators Work in Process Time Time this op/line total sec. 1/ TIME OBSERVATION SHEET Page _____ of _____ Date / Time: ___/____/____/_________________:________ Line / Process: __________________________________________________ # Step 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Complete Cycle Time 2 3 4 5 6 7 8 9 10 Observed by: _____________________________________ 11 12 13 14 15 Best Time Observations (changeover time) Time / Takt Time Bar Chart (Blank Chart) Cycle Cycle Time / Takt Time Bar Chart Cycle Time 1 2 3 4 5 9 Process 6 7 8 Cycle Time Cycle Time / Takt Time Bar Chart (with Graphing Cycle Time / Takt Time Bar Chart Feature) 1.2 1 0.8 0.6 0.4 0.2 0 Before After T/T 1 2 3 4 Process 5 6 7 Yamazumi (Stack) Chart (Blank Chart) Yamazumi (Stack) Chart Cycle Time 1 2 3 4 5 9 Process 6 7 8 Yamazumi (Stack) Chart (with Graphing Feature) Yamazumi (Stack) Chart Cycle Time Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 1 0.8 0.6 0.4 0.2 0 T/T 1 2 3 4 Process 5 6 7 Operator _____ of _____ Line: ____________________________ Process: _________________________ STANDARDIZED WORK COMBINATION SHEET Quota / Shift: ____________ Section: __________________ Takt Time: ______________ sec. AUTO: Time Step Description Man Auto Walk 1 Waiting Totals MANUAL: Date: ______/______/_______ WALKING: TIME (unit: 1 sec.) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Page ____ of ____ New / Revised as of (date): ___/___/___ Authorizations: Step Description Machine ID CAPACITY SHEETBase Times Walking Time Manual Time Part No. Max Output Part Name Auto Run Time Completion Time Current Output Line pieces per Day Needed Times: Tools Pieces/Run Change Time Time/Piece Capacity Remarks 1 Subtotal NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column. Total pieces Per Day Workers Manual Automatic Walking KAIZEN PROPOSAL SHEET Location Objective Before Problem Date Operator After Effects (cycle time / inventory / changeover time reduction,poka yoke etc.) KAIZEN NEWSPAPER DATE: _______/_______/_______/___________ TEAM: __________________________________ No. PROBLEM WHO BY WHEN CHECK Kaizen License [Name of Recipient] 改 善 John Doe Plant Manager 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 with the principles of Just in Time, Quality in Station, Production leveling, and Production Preparation. John Doe Kaizen Promotion Leader John Doe Consultant Expiration Date: [1 year from date of issuance]
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