Basic Kaizen Tools

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Step
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Best Time
Observations (changeover time)
Complete Cycle Time
Cycle Time / Time Bar Time Bar Cycle Time/ TaktTaktChart (Blank Chart) Chart
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☛If equipment seems to lack in ☛If equipment seems to lack in capacity, use Capacity Sheet to capacity, use Capacity Sheet to define problems. define problems. ☛Fill out Standardized Work ☛Fill out Standardized Work Combination Sheet with best Combination Sheet with best times. times.
☛Try out ideas for kaizen ☛Try out ideas for kaizen immediately, verify results. immediately, verify results. ☛Prepare Kaizen Proposal Sheets ☛Prepare Kaizen Proposal Sheets for effective kaizen ideas. for effective kaizen ideas.
NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.
KAIZEN PROPOSAL SHEET
Location Objective
Scope of Operation FROM: TO:
STANDARDIZED WORK SHEET
DATE: _____/____/____ Approvals:
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.
☛Note long times on Combination ☛Note long times on Combination Sheet, there are opportunities for Sheet, there are opportunities for Kaizen. Kaizen. ☛Continue to observe site, note ☛Continue to observe site, note problems on Kaizen Newspaper problems on Kaizen Newspaper
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.)
Part No. Part Name
Line Max Output per Day Tools Pieces/Run Change Time Time/Piece Capacity pieces
pieces
Auto Run Time Completion Time
Remarks
Subtotal Total
Quota / Shift: ____________ Takt Time: ______________ sec.
55 60 65 70 75 80
WALKING:
Step
Description
Man Auto Walk
85
90
1
Waiting
Totals
Page ____ of ____ New / Revised as of (date): ___/___/___
CURRENT
TARGET
DAY 1
DAY 2
DAY 3
DAY 4
FINAL RESULT
% CHANGE
REMARKS:
Process: __________________________ Part # ____________________________ Part Name: ________________________
☛Observe site. ☛Observe site. ☛Identify Process. ☛Identify Process. ☛Prepare Standardized ☛Prepare Standardized Work Sheet Work Sheet
☛Pair up 2 for each process. ☛Pair up 2 for each process. ☛One times w/ stopwatch, other jots ☛One times w/ stopwatch, other jots down times. down times. ☛Find best times. ☛Find best times. ☛Verify if Cycle Time meets Takt ☛Verify if Cycle Time meets Takt Time. Time.
Authorizations: Current Output Per Day Workers Needed
Times: Manual Automatic Walking
CAPACITY SHEET
Step Description Machine ID Walking Time Base Times Manual Time
Using the Basic Using the Basic Kaizen Tools Kaizen Tools
1 1 2 3 2 3
☛Calculate Takt Time. ☛Calculate Takt Time. ☛Identify problems. ☛Identify problems. ☛Set targets and enter on Target ☛Set targets and enter on Target Progress Report Progress Report ☛Plan & initiate Kaizen Workshop. ☛Plan & initiate Kaizen Workshop.
1/
TIME OBSERVATION SHEET
Line / Process: __________________________________________________
Page _____ of _____
Date / Time: ___/____/____/_________________:________ Observed by: _____________________________________
MANUAL: AUTO:
STANON SHEET
Time 5 10 15 20 25
Date: ______/______/_______ Section: __________________
TIME (unit: 1 sec.) 30 35 40 45 50
Date Operator
Before
After
Problem
Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)
KAIZEN NEWSPAPER
TEAM: __________________________________
BASIC KAIZEN BASIC KAIZEN TOOLS TOOLS
1. 1. 2. 2. 3. 3. 4. 4. 5. 5. 6. 6. 7. 7. 8. 8. 9. 9. TARGET PROGRESS REPORT TARGET PROGRESS REPORT STANDARDIZED WORK SHEET STANDARDIZED WORK SHEET TIME OBSERVATION SHEET TIME OBSERVATION SHEET CYCLE TIME //TAKT TIME BAR CHART CYCLE TIME TAKT TIME BAR CHART YAMAZUMI (STACK) CHART YAMAZUMI (STACK) CHART STANDARDIZED WORK COMBINATION SHEET STANDARDIZED WORK COMBINATION SHEET CAPACITY SHEET CAPACITY SHEET KAIZEN PROPOSAL SHEET KAIZEN PROPOSAL SHEET KAIZEN NEWSPAPER KAIZEN NEWSPAPER