BASIC
BASIC KAIZEN
KAIZEN
TOOLS
TOOLS
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
6.
7.
7.
8.
8.
9.
9.
TARGET
TARGET PROGRESS
PROGRESS REPORT
REPORT
STANDARDIZED
STANDARDIZED WORK
WORK SHEET
SHEET
TIME
TIME OBSERVATION
OBSERVATION SHEET
SHEET
CYCLE
CYCLE TIME
TIME // TAKT
TAKT TIME
TIME BAR
BAR CHART
CHART
YAMAZUMI
YAMAZUMI (STACK)
(STACK) CHART
CHART
STANDARDIZED
STANDARDIZED WORK
WORK COMBINATION
COMBINATION SHEET
SHEET
CAPACITY
CAPACITY SHEET
SHEET
KAIZEN
KAIZEN PROPOSAL
PROPOSAL SHEET
SHEET
KAIZEN
KAIZEN NEWSPAPER
NEWSPAPER
Using
Using the
the Basic
Basic
Kaizen
Kaizen Tools
Tools
1
1
3
3
2
2
Calculate Takt Time.
Calculate Takt Time.
Identify problems.
Identify problems.
Set targets and enter on
Set targets and enter on
Target Progress Report
Target Progress Report
Plan & initiate Kaizen
Plan & initiate Kaizen
Workshop.
Workshop.
4
4
Observe site.
Observe site.
Identify Process.
Identify Process.
Prepare Standardized
Prepare Standardized
Work Sheet
Work Sheet
5
5
If equipment seems to
If equipment seems to
lack in capacity, use
lack in capacity, use
Capacity Sheet to define
Capacity Sheet to define
problems.
problems.
Fill out Standardized
Fill out Standardized
Work Combination Sheet
Work Combination Sheet
with best times.
with best times.
6
6
Note long times on
Note long times on
Combination Sheet, there are
Combination Sheet, there are
opportunities for Kaizen.
opportunities for Kaizen.
Continue to observe site,
Continue to observe site,
note problems on Kaizen
note problems on Kaizen
Newspaper
Newspaper
7
7
Update Kaizen newspaper.
Update Kaizen newspaper.
Update Target Progress
Update Target Progress
Report.
Report.
Pair up 2 for each process.
Pair up 2 for each process.
One times w/ stopwatch,
One times w/ stopwatch,
other jots down times.
other jots down times.
Find best times.
Find best times.
Verify if Cycle Time meets
Verify if Cycle Time meets
Takt Time.
Takt Time.
Try out ideas for kaizen
Try out ideas for kaizen
immediately, verify results.
immediately, verify results.
Prepare Kaizen Proposal
Prepare Kaizen Proposal
Sheets for effective kaizen
Sheets for effective kaizen
ideas.
ideas.
Kaizen
KaizenEVERY
EVERY
DAY!!.
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
STANDARDIZED WORK SHEET
Process: __________________________
Part # ____________________________
Part Name: ________________________
Scope of
Operation
DATE: _____/____/____
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
10
Observed by: _____________________________________
11
12
13
14
15
Best Time
Observations (changeover time)
Cycle Time / Takt Time Bar Chart (Blank Chart)
Cycle Time
/ Takt Time Bar Chart
Cycle Time
1
4
8
Process
5
9
1.2
1
0.8
0.6
0.4
0.2
0
Cycle Time / Takt Time
Bar Chart (with
Graphing Feature)
Before
T/T
Yamazumi (Stack) Chart (Blank Chart)
Yamazumi
(Stack) Chart
Cycle Time
1
4
8
Process
5
9
Yamazumi (Stack) Chart
(with Graphing Feature)
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6
1
0.8
0.6
0.4
0.2
0
T/T
Operator _____ of _____
Line: ____________________________
Process: _________________________
Step
Description
STANDARDIZED
WORK
COMBINATION
SHEET
Time
Man Auto Walk
Waiting
Totals
10
15
20
MANUAL:
Date: ______/______/_______
Quota / Shift: ____________
Section: __________________
Takt Time: ______________ sec.
AUTO:
WALKING:
TIME (unit: 1 sec.)
25
30
35
40
45
50
55
60
65
70
75
80
85
90
Page ____ of ____
New / Revised as of (date): ___/___/___
Authorizations:
Step
CAPACITY
SHEET
Description
Walking Time
Manual Time
Max Output
Part Name
Auto Run Time Completion Time
Current Output
Line
pieces
per Day
Pieces/Run
Change Time
Needed
Times:
Time/Piece
Capacity
Remarks
Subtotal
NOTE
Update times when improvements are achieved through kaizen, and detail reasons for improvement in Remarks column.
Total
pieces
Per Day
Workers
Tools
Base Times
Machine
ID
Part No.
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]
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]
