Kaizen forms xls

Kaizen Tools
http://smartmanagement.info/lean-management/kaizen/kaizen-forms.html

1. BASIC KAIZEN
TOOLS
BASIC KAIZEN
TOOLS
1.TARGET PROGRESS REPORT
2.STANDARDIZED WORK SHEET
3.TIME OBSERVATION SHEET
4.CYCLE TIME / TAKT TIME BAR CHART
5.YAMAZUMI (STACK) CHART
6.STANDARDIZED WORK COMBINATION SHEET
7.CAPACITY SHEET
8.KAIZEN PROPOSAL SHEET
9.KAIZEN NEWSPAPER
1.TARGET PROGRESS REPORT
2.STANDARDIZED WORK SHEET
3.TIME OBSERVATION SHEET
4.CYCLE TIME / TAKT TIME BAR CHART
5.YAMAZUMI (STACK) CHART
6.STANDARDIZED WORK COMBINATION SHEET
7.CAPACITY SHEET
8.KAIZEN PROPOSAL SHEET
9.KAIZEN NEWSPAPER

2. 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 Report
Plan & initiate Kaizen
Workshop.
Calculate Takt Time.
Identify problems.
Set targets and enter on
Target Progress Report
Plan & 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.
11
11
22
22 33
33
44
44
55
55
66
66
77
77
¥¥
¥¥

3. 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

4. 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

5. TIME OBSERVATION SHEET
Line / Process: __________________________________________________
Date / Time: ___/____/____/_________________:________
Observed by: _____________________________________
Page _____ of _____
# Step 123456789101112131415 Best TimeObservations (changeover time)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Complete Cycle Time
0

6. Cycle Time / Takt Time Bar Chart (Blank Chart)
Cycle Time / Takt Time Bar Chart
C
y
c
l
e

T
i
m
e
Process
1 2 3 4 5 6 7
8 9

7. Cycle Time / Takt Time
Bar Chart (with Graphing
Feature)
Cycle Time / Takt Time Bar Chart
0
0.2
0.4
0.6
0.8
1
1.2
Process
C
y
c
le

T
im
e
Before
After
1 2 3 4 5 6 7
T/T

8. Yamazumi (Stack) Chart (Blank Chart)
Yamazumi (Stack) Chart
C
y
c
l
e

T
i
m
e
Process
1 2 3 4 5 6 7
8 9

9. Yamazumi (Stack) Chart
0
0.2
0.4
0.6
0.8
1
1 2 3 4 5 6 7
Process
C
y
c
l
e

T
i
m
e
Task 1Task 2Task 3Task 4Task 5Task 6
Yamazumi (Stack) Chart
(with Graphing Feature)
T/T

10. Line: ____________________________
Process: _________________________
Date: ______/______/_______
Section: __________________
Quota / Shift: ____________
Takt Time: ______________ sec.
Operator _____ of _____
MANUAL:
AUTO:
WALKING:
Step Description
Time
ManAutoWalk
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

11. Part Name
Part No.
Max Output
per Day
Line
pieces
Workers
Needed
Current Output
Per Day
pieces
Page ____ of ____
Step Description
Machine
ID
Tools
Capacity
Base Times
Walking TimeManual TimeAuto Run TimeCompletion TimePieces/RunChange TimeTime/Piece
Remarks
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

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

13. KAIZEN NEWSPAPER
TEAM: __________________________________ DATE: _______/_______/_______/___________
No. PROBLEM WHO BY WHEN CHECK

14. 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