BASIC KAIZEN TOOLS

BASIC KAIZEN TOOLS

1. TARGET PROGRESS REPORT2. STANDARDIZED WORK SHEET3. TIME OBSERVATION SHEET4. CYCLE TIME / TAKT TIME BAR CHART5. YAMAZUMI (STACK) CHART6. STANDARDIZED WORK COMBINATION SHEET7. CAPACITY SHEET8. KAIZEN PROPOSAL SHEET9. KAIZEN NEWSPAPER

1. TARGET PROGRESS REPORT2. STANDARDIZED WORK SHEET3. TIME OBSERVATION SHEET4. CYCLE TIME / TAKT TIME BAR CHART5. YAMAZUMI (STACK) CHART6. STANDARDIZED WORK COMBINATION SHEET7. CAPACITY SHEET8. KAIZEN PROPOSAL SHEET9. KAIZEN NEWSPAPER

Using the Basic Kaizen Tools

Using the Basic Kaizen Tools

If equipment seems to lack in capacity, use Capacity Sheet to define problems.Fill out Standardized Work Combination Sheet with best times.

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

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.

Try out ideas for kaizen immediately, verify results.Prepare Kaizen Proposal Sheets for effective kaizen ideas.

Update Kaizen newspaper.Update Target Progress Report.

Update Kaizen newspaper.Update Target Progress Report.

Calculate Takt Time.Identify problems.Set targets and enter on Target Progress ReportPlan & initiate Kaizen Workshop.

Calculate Takt Time.Identify problems.Set targets and enter on Target Progress ReportPlan & initiate Kaizen Workshop.

Kaizen EVERY DAY!!.

Kaizen EVERY DAY!!.

Observe site.Identify Process.Prepare Standardized Work Sheet

Observe site.Identify Process.Prepare Standardized Work Sheet

Pair up 2 for each process.One times w/ stopwatch, other jots down times.Find best times.Verify if Cycle Time meets Takt Time.

Pair up 2 for each process.One times w/ stopwatch, other jots down times.Find best times.Verify if Cycle Time meets Takt Time.

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2222 33

33

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TARGET PROGRESS REPORTDepartment / 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: ________________________

Scope of Operation

FROM:

TO:

DATE: _____/____/____

Takt

Time

sec.

Cycle

Time

Operators

this op/line total

1 /

Total Pcs of Std

Work in Process

Standard Work

In Process

Safety

Precaution

Quality

Check

Approvals:

SYMBOLS BASIC

DATA

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.

STANDARDIZED WORK SHEET

TIME OBSERVATION SHEET

Line / Process: __________________________________________________Date / Time: ___/____/____/_________________:________

Observed by: _____________________________________

Page _____ of _____

# Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Best Time Observations (changeover time)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Complete Cycle Time

0

Cycle Time / Takt Time Bar Chart (Blank Chart)Cycle Time / Takt Time Bar Chart

Cycle

Tim

e

Process

1 2 3 4 5 6 7 8

Cycle Time / Takt Time Bar Chart (with

Graphing Feature)Cycle Time / Takt Time Bar Chart

00.20.40.60.8

11.2

Process

Cycl

e T

ime

BeforeAfter

1 2 3 4 5 6 7

T/T

Yamazumi (Stack) Chart (Blank Chart)Yamazumi (Stack) Chart

Cycle

Tim

e

Process

1 2 3 4 5 6 7 8

Yamazumi (Stack) Chart

00.20.40.60.8

1

1 2 3 4 5 6 7

Process

Cycle

Tim

e

Task 1 Task 2 Task 3 Task 4 Task 5 Task 6

Yamazumi (Stack) Chart (with Graphing Feature)

T/T

Line: ____________________________

Process: _________________________

Date: ______/______/_______

Section: __________________

Quota / Shift: ____________

Takt Time: ______________ sec.

Operator _____ of _____

MANUAL:

AUTO:

WALKING:

Step DescriptionTime

Man Auto Walk

TIME (unit: 1 sec.)

Waiting

Totals

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

1

STANDARDIZED WORK

COMBINATION SHEET

Part Name

Part No.

Max Output

per Day

Line

piecesWorkers

Needed

Current Output

Per Daypieces

Page ____ of ____

Step DescriptionMachine

ID

ToolsCapacity

Base Times

Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/PieceRemarks

Times: Manual

Automatic

Walking

１

Subtotal

Total

NOTE

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

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

Authorizations:

CAPACITY SHEET

Before After

Location Objective Date Operator

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

KAIZEN PROPOSAL SHEET

KAIZEN NEWSPAPER

TEAM: __________________________________ DATE: _______/_______/_______/___________

No. PROBLEM WHO BY WHEN CHECK

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.

[Name of Recipient]

Expiration Date: [1 year from date of issuance]

John Doe

Plant Manager

John Doe

Kaizen Promotion Leader

John Doe

Consultant

改善

Kaizen License