BASIC KAIZEN TOOLS

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]