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BASIC KAIZEN TOOLS. 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. 3. 1. 2.

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basic kaizen tools

BASIC KAIZEN TOOLS

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

Using the Basic Kaizen Tools

3

1

2

  • Pair up 2 for each process.
  • One times w/ stopwatch, other jots down times.
  • Find best times.
  • Verify if Cycle Time meets Takt Time.
  • Calculate Takt Time.
  • Identify problems.
  • Set targets and enter on Target Progress Report
  • Plan & initiate Kaizen Workshop.
  • Observe site.
  • Identify Process.
  • Prepare Standardized Work Sheet

4

5

6

  • If equipment seems to lack in capacity, use Capacity Sheet to define problems.
  • Fill out Standardized Work Combination Sheet with best times.
  • Note long times on Combination Sheet, there are opportunities for Kaizen.
  • Continue to observe site, note problems on Kaizen Newspaper
  • Try out ideas for kaizen immediately, verify results.
  • Prepare Kaizen Proposal Sheets for effective kaizen ideas.

7

  • Update Kaizen newspaper.
  • Update Target Progress Report.
  • Kaizen EVERY DAY!!.
target progress report
TARGET PROGRESS REPORT

Department / Section / Site

Date: ___/____/____/____/__________

Takt Time: _______________________

CATEGORY

CURRENT

TARGET

DAY 1

DAY 2

DAY 3

DAY 4

FINAL RESULT

% CHANGE

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:

standardized work sheet
STANDARDIZED WORK SHEET

DATE: _____/____/____

Approvals:

Process: __________________________

Part # ____________________________

Part Name: ________________________

Scope of Operation

FROM:

TO:

SYMBOLS

Quality

Check

Safety

Precaution

Standard Work

In Process

Total Pcs of Std

Work in Process

Takt

Time

Cycle

Time

Operators

this op/line total

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.

BASIC

DATA

sec.

1 /

time observation sheet
TIME OBSERVATION SHEET

Page _____ of _____

Date / Time: ___/____/____/_________________:________

Observed by: _____________________________________

Line / Process: __________________________________________________

#

Step

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Best Time

Observations (changeover time)

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Complete Cycle Time

cycle time takt time bar chart blank chart

Cycle Time

1 2 3 4 5 6 7 8 9

Process

Cycle Time / Takt Time Bar Chart

Cycle Time / Takt Time Bar Chart (Blank Chart)
yamazumi stack chart blank chart

Cycle Time

1 2 3 4 5 6 7 8 9

Process

Yamazumi (Stack) Chart

Yamazumi (Stack) Chart (Blank Chart)
standardized work combination sheet
STANDARDIZED WORK COMBINATION SHEET

Operator _____ of _____

Line: ____________________________

Date: ______/______/_______

Quota / Shift: ____________

MANUAL:

AUTO:

WALKING:

Process: _________________________

Section: __________________

Takt Time: ______________ sec.

Step

Description

Time

TIME (unit: 1 sec.)

Man

Auto

Walk

65

70

75

80

85

90

5

10

15

20

25

30

35

40

45

50

55

60

1

Totals

Waiting

capacity sheet
CAPACITY SHEET

Page ____ of ____

New / Revised as of (date): ___/___/___

Part No.

Line

Current Output

Per Day

pieces

Authorizations:

Part Name

Max Output

per Day

pieces

Workers

Needed

Times: Manual

Automatic

Walking

Step

Description

Machine

ID

Tools

Capacity

Remarks

Base Times

Walking Time

Manual Time

Auto Run Time

Completion Time

Pieces/Run

Change Time

Time/Piece

Subtotal

NOTE

Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.

Total

kaizen proposal sheet
KAIZEN PROPOSAL SHEET

Location

Objective

Date

Operator

Before

After

Problem

Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

kaizen newspaper
KAIZEN NEWSPAPER

DATE: _______/_______/_______/___________

TEAM: __________________________________

No.

PROBLEM

WHO

BY WHEN

CHECK

kaizen license
Kaizen License

[Name of Recipient]

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

John Doe

Plant Manager

Expiration Date: [1 year from date of issuance]