BASIC

BASIC KAIZEN
KAIZEN
TOOLS
TOOLS
1.
1. TARGET
TARGETPROGRESS
PROGRESSREPORT
REPORT
2.
2. STANDARDIZED
STANDARDIZEDWORK
WORKSHEET
SHEET
3.
3. TIME
TIMEOBSERVATION
OBSERVATIONSHEET
SHEET
4.
4. CYCLE
CYCLETIME
TIME//TAKT
TAKTTIME
TIMEBAR
BARCHART
CHART
5.
5. YAMAZUMI
YAMAZUMI(STACK)
(STACK)CHART
CHART
6.
6. STANDARDIZED
STANDARDIZEDWORK
WORKCOMBINATION
COMBINATIONSHEET
SHEET
7.
7. CAPACITY
CAPACITYSHEET
SHEET
8.
8. KAIZEN
KAIZENPROPOSAL
PROPOSALSHEET
SHEET
9.
9. KAIZEN
KAIZENNEWSPAPER
NEWSPAPER
 Using
Usingthe
theBasic
Basic
Kaizen
KaizenTools
Tools
3
1 2 3
1 2

☛Pair up 2 for each process.

☛Calculate Takt Time. ☛Pair up 2 for each process.
☛Calculate Takt Time. ☛Observe site. ☛One times w/ stopwatch, other jots
☛Identify problems. ☛Observe site. ☛One times w/ stopwatch, other jots
☛Identify problems. ☛Identify Process. down times.
☛Set targets and enter on Target ☛Identify Process. down times.
☛Set targets and enter on Target ☛Prepare Standardized ☛Find best times.
Progress Report ☛Prepare Standardized ☛Find best times.
Progress Report Work Sheet ☛Verify if Cycle Time meets Takt
☛Plan & initiate Kaizen Workshop. Work Sheet ☛Verify if Cycle Time meets Takt
☛Plan & initiate Kaizen Workshop. Time.
Time.

4
4 5
☛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 6
☛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
☛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. ☛Kaizen
☛KaizenEVERY
EVERYDAY!!.
DAY!!.
☛Update Target Progress Report.
 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:
 DATE: _____/____/____
STANDARDIZED WORK SHEET
Process: __________________________ Approvals:
Part # ____________________________ Scope of
FROM:
Operation
Part Name: ________________________ TO:

SYMBOLS Quality Safety Standard Work Total Pcs of Std Takt Cycle Operators
NOTE: Takt Time, Work Sequence (same as numbers in “Step” column on BASIC
Check Precaution In Process Work in Process Time Time this op/line total
Combination Sheet), and numbers of Standard Work in Process must be
known to define Standardized Work. Identify all safety concerns, points where DATA
1/
quality must be verified (go/no-go) and numbers of pieces of standard work in sec.
process using the symbols to the right.
 Page _____ of _____
TIME OBSERVATION SHEET
Date / Time: ___/____/____/_________________:________
Line / Process: __________________________________________________
Observed by: _____________________________________

# Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Best Time Observations (changeover time)

0
1

10

11

12

13

14

15

Complete Cycle Time

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

1 2 3 4 5 6 7 8 9
Process
 Yamazumi
Yamazumi (Stack) (Stack) Chart
Chart (Blank Chart)
Cycle Time

1 2 3 4 5 6 7 8 9
Process
 Operator _____ of _____

Line: ____________________________ MANUAL:

STANDARDIZED WORK Date: ______/______/_______ Quota / Shift: ____________
AUTO:
Process: _________________________
COMBINATION SHEET Section: __________________ Takt Time: ______________ sec. WALKING:

Time TIME (unit: 1 sec.)

Step Description
Man Auto Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

Waiting
Totals
 Page ____ of ____
  New / Revised as of (date): ___/___/___
Current Output
Authorizations: Part No. Line pieces
Per Day
CAPACITY SHEET Part Name
Max Output
pieces
Workers
per Day Needed
Times: Manual
Machine Base Times Tools
Step Description Capacity Remarks Automatic
ID Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/Piece Walking

Subtotal NOTE
Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.
Total
 KAIZEN PROPOSAL SHEET

Location Objective Date Operator

Before After

Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)
 KAIZEN NEWSPAPER
TEAM: __________________________________ DATE: _______/_______/_______/___________

No. PROBLEM WHO BY WHEN CHECK