kaizen forms xls
TRANSCRIPT
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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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 9
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 9
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]
改善
Kaizen License