TARGET TARGET PROGRESS PROGRESS REPORT REPORT

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1 BASIC KAIZEN TOOLS TARGET PROGRESS REPORT STANDARDIZED WORK SHEET TIME OBSERVATION SHEET CYCLE TIME // TAKT TIME BAR BAR CHART YAMAZUMI (STACK) CHART STANDARDIZED WORK COMBINATION SHEET CAPACITY SHEET KAIZEN PROPOSAL SHEET KAIZEN NEWSPAPER

2 Using the Basic Kaizen Tools 1 1 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 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. 4 4 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. 5 5 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 6 6 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. 7 7 Update Kaizen newspaper. Update Kaizen newspaper. Update Target Progress Report. Update Target Progress Report. Kaizen Kaizen EVERY EVERY DAY!!. DAY!!.

3 TARGET PROGRESS REPORT Department / Section / Site Date: / / / / Takt Time: CATEGORY CURRENT TARGET DAY 1 DAY 2 DAY 3 DAY 4 FINAL RESULT % CHANGE 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:

4 Process: STANDARDIZED WORK SHEET DATE: / / Approvals: Part # Part Name: Scope of Operation 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 Check Safety Precaution Standard Work In Process BASIC DATA Total Pcs of Std Work in Process Takt Time sec. Cycle Time Operators this op/line total 1 /

5 TIME OBSERVATION SHEET Page of Line / Process: Date / Time: / / / : Observed by: # Step Best Time Observations (changeover time) Complete Cycle Time

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

7 Yamazumi (Stack) (Stack) Chart (Blank Chart) Chart Cycle Time Process

8 Operator of Line: Process: STANDARDIZED WORK COMBINATION SHEET Date: / / Section: Quota / Shift: Takt Time: sec. MANUAL: AUTO: WALKING: Step Description Time Man Auto Walk TIME (unit: 1 sec.) Totals Waiting

9 New / Revised as of (date): / / Page of Authorizations: CAPACITY SHEET Part No. Part Name Line Max Output per Day pieces Current Output Per Day Workers Needed pieces Step Description Machine ID Base Times Tools Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/Piece Capacity Remarks Times: Manual Automatic Walking Subtotal Total NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in Remarks column.

10 KAIZEN PROPOSAL SHEET Location Objective Date Operator Before After Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

11 KAIZEN NEWSPAPER TEAM: DATE: / / / No. PROBLEM WHO BY WHEN CHECK

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