KaiZen

( )

1434-1433

 :
120

:
.

.
.

.
/ .

.
.
.

 :
/

:
/ / :
-1 .
-2 .
-3 ( )
.
-4 .
-5 .
-6 .
-7
.
-8
.
-9 (.)S 5

/ / :
.1 .
.2 .
.3 .
.4 ( )
.
.5 .


:
-

1
2

( )

( )

6
7
8

....


...
:

:
.

 KaiKaku

Kaku
Radical

Kai
Change

:
.



% 60

%15

:
60
%25
% 15

Abrupt

Gradual
(
)

 VS



Kaizen Suggesting System

Suggesting System

.
.

 M's 3
Lean System

M's 3 :
Muda Wastes 7
Mura
Muri

 :Muda
.
:Mura
( )
.
:Muri

.

 Wastes 7

Muda :
.1 Waste of overproduction
.2 Waste of waiting times
.3 Waste of transportation and handling
.4 Waste related to useless
and excess inventories
.5 Waste in production process
.6 Useless motions
.7 Waste from scrap and defects

 : PDCA
Deming Cycle
Shewhart Cycle

 PDCA DMAIC Sigma 6

DMAIC :

 Problem Solving
:
o ( )
o Whys 5
o (Ishikawa) Fish Bone

 : ( )
:
....................................................................................
....................................................................................
....................................................................................
........................................................................

 : Whys 5



.
:

 : Fish Bone
Ishikawa
...

...

...
.

 : Fish Bone
Ishikawa
:

 30

/ / :
.1 .Gemba Kaizen
.2 .
.3 .
.4
.5
( TPS,JIT,Kanaban, Jidoka, Andon, Poka-
)Yoke, Genchi Genbutsu, Heijunka, Hansei
.6 S,s5 .

 Gemba Kaizen
gemba kaizen:

.. ..

..
.

5
:Golden Roles
.1 .
.2 Genchi
.Genbutsu
.3
.4
.5 .

:
.
.
.
.
.PDCA

Toyota Production
System TPS

 TPS:


.
TPS:
.
.
.

.


:Total Productive Maintenance TPM

..
:





.

.
.

.
.
.

 Just in Time
JIT




.

System

Pull

Push System

 :Kanaban System
..

.. JIT









.

 Jidoka
..



.
: Jidoka
.
.
.
(
).

Automation with a
human touch

Automatic Operation

() Jidoka

 Andon

...






. Jidoka

 : Poka-Yoke

.
.
:

.

 : Reduce Chance Of
:) Occurrence ( RCO



:
.
.
.

: Increase Chance Of
:) Detection( ICD




:

.
.

.

 : Genchi Genbutsu

.

gemba

....
.

 Genchi Genbutsu
: Ohno

"
"

Ohno
... Taiichi Ohno
...
gemba
.

 Heijunka
:
"
"


: Hansei

" ...

...
"
"

S's 5
S s'5

Sort

Sei-ri

Stabilize

Sei-ton

Shine

Sei-so

Standardize

Sei-ke-tsu

Sustain

Shi-tsu-ke

Seiri


Seiton


.
30 :
30 .
:

.

.

 Seiso
.
...
%15 %20
:
.
.
.
.
.
:
.S5
.
.

Seiketsu

( ) :
:
.
():
.
.

 Shitsuke

.

STANDARDIZED WORK SHEET

Process :
__________________________
Part #
____________________________

Approvals:

FROM:

Scope of
Operation

TO:

Part Name :
________________________

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.

DATE____/____/_____ :

SYMBO
LS

Quality
Check

Safety
Precaution

Standard
Work
In Process

BASIC
DATA

Total Pcs of
Std
Work in
Process

Takt
Time

Cycle
Time

Operators
this op/line
total

/1
sec.

TIME OBSERVATION SHEET

Page _____ of_____

Date / Time________:_________________/____/____/___ :
Line / Process__________________________________________________ :

Step

1
0

10

11

Observed by_____________________________________ :
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

Page ____ of____

New / Revised as of (date ___/___/___ :)
Authorizations:

CAPACITY SHEET
Ste
p

Description

Machin
e
ID

Part Name

Manual
Time

Auto Run
Time

Current
Output

Max Output

Per Day
Workers

pieces

per Day
Tools

Base Times
Walking
Time

Line

Part No.

Completion
Time

Pieces/Run

Change
Time

Time/Piece

Capaci
ty

pieces

Needed
Times:
Manual
Automatic

Remarks

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

Before

Problem

Date

After

Effects (cycle time / inventory / changeover time

reduction,poka yoke etc).

Opera
tor

KAIZEN NEWSPAPER
DATE___________/_______/_______/_______ :

TEAM__________________________________ :
No.

PROBLEM

WHO

BY WHEN

CHEC
K


:
-

1
2

( )

( )

6
7
8