Kaizen

Joseph P. Vitalo

Frank Butz

Raphael L. Vitalo, Ph.D.

Kaizen Tool Kit

Kaizen Tool KitRaphael L. Vitalo, Ph.D., Frank Butz, and Joseph P. Vitalo

ISBN 0-9722810-3-7Version 1.5

Copyright © 2003 Vital Enterprises, Hope, ME 04847

All rights reserved.

Image Copyright, New Vision Technologies Incorporated

Printed in the United States of AmericaNo part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any

method, such as electronic, mechanical, photocopying, recording, or otherwise without prior written consent of VitalEnterprises.

InstructionsAccessing Tools

Click here to access tools by selecting the milestone,task, or step on which you are working.

Click here to access tools from an alphabetical listing ofABCall tools.

Saving FormsCreate a folder on your hard disk drive in which to store therecords of your Kaizen event. Name the folder with the loca-tion and date of your event—e.g., Savannah11-02-05Once you have opened a form, save it under a new name tothe folder you created. Label the file with the name of theform and where your event was performed—e.g., Summaryof Findings-Savannah.

Click on ActivityorClick Here forA List of Tools

To Accessa Tool...

Institutionalizethe ProcessImprovements

Milestone

to Conduct the Analyze Whether

Kaizen Event

Prepare for the Kaizen Event

Perform theKaizen Event

Document aScope for theKaizen Event

CMilestone

AMilestone

EMilestone

BMilestone

D

Task D2

Focus theKaizen Event

Evaluate theTarget WorkProcess

Solve thePerformanceIssue

Act to Improve the Target WorkProcess

Task D3 Task D4 Task D1

Build MeasurePilotWalk Through

MissionGoalsDo's and Don'ts

ABCDon't Forget toS e n d U s F e e d b a c kClick Here for Form

ENDSTART

Experiment

Milestone A. Document a Scope for the Kaizen EventPurpose

To gather information that defines the focus, boundaries, and expectationsfor performing a Kaizen event.

ToolsGuide: The Event Coordinator RoleGuide: The Role of Providing Scope InformationTimeline for Completing a Kaizen EventKaizen Scope DocumentScope Statement ChecklistChecking Consistency of Scope Information

Milestone B. Analyze Whether to Conduct the Kaizen EventPurpose

To judge whether holding the Kaizen event is likely to produce the businessbenefits sought by the people requesting the event.

ToolsLogistics ChecklistResults of Judging the Appropriateness of Doing the Kaizen EventStrawperson Direction for the Proposed Event

Milestone C. Prepare for the Kaizen EventPurpose

To advance the success of the Kaizen event by readying the people, setting,and resources needed to conduct it.

ToolsGuide: Explaining What Kaizen IsGuide: Judging Readiness for the EventKaizen News - Days 1-5Kaizen Post-Event FlyerKaizen Pre-Event FlyerLogistics ChecklistStakeholder PerspectiveTravel and Shipping Arrangements Job Aid

Milestone D. Perform the Kaizen EventPurpose

To uncover and eliminate waste in a work process in a manner that accom-plishes the business’s purposes.

ToolsCertificate of RecognitionChecklist for Preparing the SettingKaizen Participant Feedback FormKaizen Participant Feedback Summary FormKaizen SummaryParking Lot IssuesWorking With Others 10 Minute Review - Instructor GuideWorking With Others 10 Minute Review - Visuals

Task D1. Focus the Kaizen EventPurpose

To define the direction the Kaizen event will pursue based on the facts in theworkplace.

ToolsDetecting Value-Added Work and the Forms of Waste ExerciseDirection for the Kaizen Event (includes mission statement, goals for theevent, and do’s and don’ts)Guide: Observe FirstGuide: Understanding the Forms of WasteQuestions That Could Be Asked During the Personal InterviewQuestions That Could Be Asked During the Walk ThroughWaste Observed During Walk Through Categorized by Type

Step D1-S1. Build a Description of the Target Work ProcessPurpose

To equip the team with a common image of the target work process to guideits information gathering and process improvement efforts.

ToolsGuide for Documenting Decision LogicTemplate for Describing a Work Process

Step D1-S2. Walk Through the Target Work ProcessPurpose

To gather information about the work process and any instances of wastewithin it so that you can define a mission and set goals for the event.

ToolsDetecting Value-Added Work and the Forms of Waste ExerciseGuide: Observe FirstGuide: Questions That Could Be Asked During the Personal InterviewGuide: Questions That Could Be Asked During the Walk ThroughGuide: Understanding the Forms of WasteWaste Observed During Walk Through Categorized by Type

Step D1-S3. Build the Mission StatementPurpose

To identify the business results the event should produce and the work proc-ess improvement that will produce them using the results of the walkthrough.

ToolsDirection for the Kaizen Event (use this form to record the mission state-ment, goals for the event, and do’s and don’ts)

Step D1-S4. Set Goals for the Kaizen EventPurpose

To set measurable targets for eliminating waste in the target work processusing the results of the walk through.

ToolsDirection for the Kaizen Event (use the file in which you recorded theevent’s mission statement)

Step D1-S5. Define the Do’s and Don’tsPurpose

To understand what the Kaizen team may and may not do as it improves thetarget work process.

ToolsDirection for the Kaizen Event (use the file in which you recorded theevent’s mission statement)

Task D2. Evaluate the Target Work ProcessPurpose

To produce an exact measure of the types and amount of waste occurring inthe target work process.

ToolsGuide: Distance Measurement RoleGuide: Documentation RoleGuide: Machine Observer RoleGuide: Photographer RoleGuide: Process Observer RoleGuide: Spaghetti Charting RoleGuide: Timekeeper RoleGuide: Understanding the Forms ofWasteGuide: Utility Role

Guide: Workplace Layout RoleMachine Analysis SheetMachine Observations Data SheetParking Lot IssuesProcess Analysis SheetProcess Observations Data SheetSharpening Observation SkillsExerciseSummary of FindingsUsing the Machine Analysis Sheet

Task D3. Solve the Performance IssuePurpose

To conceive and select the best ways to achieve the Kaizen event’s goals.

ToolsDesign of the ExperimentGuide: Designing the ExperimentParking Lot Issues (if you already began to list Parking Lot Issues, usethe file in which you recorded those issues)Prioritized List of Process and Workplace Improvement IdeasResults of the Experiment

Step D3-S3. Conduct an ExperimentPurpose

To test the effectiveness of an improvement idea in eliminating waste.

ToolsDesign of the Experiment (Form)Guide: Designing an ExperimentResults of the Experiment (Form)

Task D4. Act to Improve the Target Work ProcessPurpose

To execute the selected improvement ideas successfully.

ToolsAction Plan ExampleAction Plan TemplateDesign of the PilotGuide: Building an Action PlanGuide: Planning the PilotResults of the PilotSummary of Monetary BenefitsSummary of Operating Improvements Template for Leave-Behind Measure

Step D4-S1. Measure ResultsPurpose

To detect and quantify the work process and business benefits produced bythe Kaizen event.

ToolsSummary of Monetary BenefitsSummary of Operating Improvements

Step D4-S3. Conduct a PilotPurpose

To implement an improvement for a portion of a work process or workplace.

ToolsDesign of the PilotGuide: Planning the PilotResults of the Pilot

Milestone E. Institutionalize the Process ImprovementsPurpose

To ensure that the improvements made by the Kaizen event generate maxi-mum benefits for the business and its stakeholders.

ToolsNone.

Action Plan ExampleAction Plan TemplateCertificate of RecognitionConsistency of Scope InformationChecklist for Preparing the SettingDesign of the PilotDetecting Value-Added Work and the Forms of WasteExerciseDirection for the Kaizen EventDo’s and Don’tsExperiment, Design/Results ofGoals for the EventGuide: Building an Action PlanGuide: Designing the ExperimentGuide: Distance Measurement RoleGuide: Documentation RoleGuide: Documenting Decision LogicGuide: Explaining What Kaizen IsGuide: Judging Readiness for the EventGuide: Machine Observer Role

Guide: Observe FirstGuide: Photographer RoleGuide: Planning the PilotGuide: Process Observer RoleGuide: Questions That Could Be Asked During the PersonalInterviewGuide: Questions That Could Be Asked During the WalkThroughGuide: Spaghetti Charting RoleGuide: The Event Coordinator RoleGuide: The Role of Providing Scope InformationGuide: Timekeeper RoleGuide: Understanding the Forms of WasteGuide: Utility RoleGuide: Workplace Layout RoleKaizen News - Days 1-5Kaizen Participant Feedback FormKaizen Participant Feedback Summary FormKaizen Post-Event Flyer

Index of Tools

Kaizen Pre-Event FlyerKaizen Scope DocumentKaizen SummaryLeave-Behind MeasureLogistics ChecklistMachine Analysis SheetMachine Observations Data SheetMission StatementParking Lot IssuesPilot , Guide: Planning the Pilot , Results of the Prioritized List of Process and Workplace ImprovementIdeasProcess Analysis SheetProcess Observations Data SheetResults of Judging the Appropriateness of Doing the KaizenEventScope DocumentScope Statement ChecklistSharpening Observation Skills Exercise

Stakeholder PerspectiveStrawperson Direction for the Proposed EventSummary of FindingsSummary of Monetary BenefitsSummary of Operating Improvements Timeline for Completing a Kaizen EventTemplate for Describing a Work ProcessTemplate for Leave-Behind MeasureTravel and Shipping Arrangements Job AidUser Evaluation and Feedback FormUsing the Machine Analysis SheetUsing the Process Analysis SheetWaste Observed During Walk Through Categorized by TypeWorking With Others 10 Minute Review - Instructor GuideWorking With Others 10 Minute Review - Visuals

Index of Tools

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