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
!. STANDARDIZED WORK COMBINATION SHEET
". CAPACITY SHEET
#. KAIZEN PROPOSAL SHEET
$. 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
!. STANDARDIZED WORK COMBINATION SHEET
". CAPACITY SHEET
#. KAIZEN PROPOSAL SHEET
$. KAIZEN NEWSPAPER

U%&'( )*+ B,%&-
K,&.+' T//0%
U%&'( )*+ B,%&-
K,&.+' T//0%
If equipment seems to
lack in capacity, use
Capacity Sheet to defne
problems.
Fill out Standardized
Work Combination Sheet
with best times.
If equipment seems to
lack in capacity, use
Capacity Sheet to defne
problems.
Fill out Standardized
Work Combination Sheet
with best times.
ote lon! times on
Combination Sheet, there are
opportunities for "aizen.
Continue to obser#e site,
note problems on "aizen
ewspaper
ote lon! times on
Combination Sheet, there are
opportunities for "aizen.
Continue to obser#e site,
note problems on "aizen
ewspaper
$ry out ideas for kaizen
immediately, #erify results.
%repare "aizen %roposal
Sheets for e&ecti#e kaizen
ideas.
$ry out ideas for kaizen
immediately, #erify results.
%repare "aizen %roposal
Sheets for e&ecti#e kaizen
ideas.
'pdate "aizen newspaper.
'pdate $ar!et %ro!ress
(eport.
'pdate "aizen newspaper.
'pdate $ar!et %ro!ress
(eport.
Calculate $akt $ime.
Identify problems.
Set tar!ets and enter on
$ar!et %ro!ress (eport
%lan ) initiate "aizen
Workshop.
Calculate $akt $ime.
Identify problems.
Set tar!ets and enter on
$ar!et %ro!ress (eport
%lan ) initiate "aizen
Workshop.
"aizen *+*(,
-.,//.
"aizen *+*(,
-.,//.
0bser#e site.
Identify %rocess.
%repare Standardized
Work Sheet
0bser#e site.
Identify %rocess.
%repare Standardized
Work Sheet
%air up 1 for each process.
0ne times w2 stopwatch,
other 3ots down times.
Find best times.
+erify if Cycle $ime meets
$akt $ime.
%air up 1 for each process.
0ne times w2 stopwatch,
other 3ots down times.
Find best times.
+erify if Cycle $ime meets
$akt $ime.
4 4
4 4
1 1
1 1 5 5
5 5
6 6
6 6
7 7
7 7
8 8
8 8
9 9
9 9



TARGET PROGRESS REPORT
Department / Section / Site
Date: ___/____/____/____/__________
Takt Time: _______________________
CATEGORY
SPACE (sq. ft.)
INVENTORY
WA!ING DISTANCE
"ATERIA TRAVE DISTANCE
EAD TI"E (se#.)
CYCE TI"E (se#.)
O$TP$T (%&its / 'a()
CREW SI)E
PROD$CTIVITY
C*ANGEOVER TI"E (se#.)
RE"AR!S:
C$RRENT TARGET DAY + DAY , DAY - DAY . /INA RES$T 0 C*ANGE

P12#ess: __________________________
Pa1t 3 ____________________________
Pa1t Name: ________________________
Scope of
Operation
FROM:
TO:
DATE: _____/____/____
Takt
Time
sec.
Cycle
Time
Operators
this op/line total
1 /
Total Pcs of Std
ork in Process
Standard ork
!n Process
Safety
Preca"tion
#"ality
Check
$ppro%als:
S&M'O(S
'$S!C
D$T$
)OT*: Takt Time+ ork Se,"ence -same as n"m.ers in /Step0 col"mn on
Com.ination Sheet1+ and n"m.ers of Standard ork in Process m"st .e
kno2n to define Standardi3ed ork. !dentify all safety concerns+ points 2here
,"ality m"st .e %erified -4o/no54o1 and n"m.ers of pieces of standard 2ork in
process "sin4 the sym.ols to the ri4ht.
STANDARDIZED WORK SHEET

TIME OBSERVATION SHEET
i&e / P12#ess: __________________________________________________
Date / Time: ___/____/____/_________________:________
O4se15e' 4(: _____________________________________
Pa6e _____ 2f _____
3 Ste7 + , - . 8 9 : ; < += ++ +, +- +. +8 >est Time O4se15ati2&s -chan4eo%er time1
+
,
-
.
8
9
:
;
<
+=
++
+,
+-
+.
+8
C2m7?ete C(#?e Time
=

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+

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+
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# $

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9
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9.#
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!
T/T

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# $

T,%3 1 T,%3 2 T,%3 3 T,%3 4 T,%3 5 T,%3 !
9
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(5&)* G4,6*&'( 7+,)84+
T/T

i&e: ____________________________
P12#ess: _________________________
Date: 666666/666666/6666666
Section: 666666666666666666
#"ota / Shift: 666666666666
Takt Time: 66666666666666 sec.
O7e1at21 _____ 2f _____
M$)7$(:
$7TO:
$(8!)9:
Step Description
Time
Man $"to alk
TI"E (%&it: + se#.)
aitin4
Totals
: 1; 1: <; <: =; =: >; >: :; :: ?; ?: @; @: A; A: B;
1
STANDARDIZED
WORK
COMBINATION
SHEET

Pa1t Name
Pa1t N2.
MaC O"tp"t
per Day
i&e
pieces
orkers
)eeded
C"rrent O"tp"t
Per Day
pieces
Page ____ of ____
Step Description
Machine
!D
Tools
Capacity
'ase Times
alkin4 Time Man"al Time $"to R"n Time Completion Time Pieces/R"n Chan4e Time Time/Piece
Rema1ks
Times: Man"al
$"tomatic
alkin4


















S".total
T2ta?
NOTE
$7'ate times @Ae& im7125eme&ts a1e a#Aie5e' tA12%6A kaiBe&C a&' 'etai? 1eas2&s f21 im7125eme&t i& DRema1ksE #2?%m&.
New / Revised as of (date): ___/___/___
Authorizations:
CAPACITY
SHEET

>ef21e Afte1
(ocation O.Decti%e Date Operator
P124?em Effe#ts -cycle time / in%entory / chan4eo%er time red"ction+poka yoke etc.1
KAIZEN PROPOSAL SHEET

KAIZEN NEWSPAPER
TEA": __________________________________
DATE: _______/_______/_______/___________
N2. PRO>E" W*O >Y W*EN C*EC!

In recognition of your earnest eforts
to learn and practice kaizen during
the [XXX] Kaizen Workshop held at
[XXX] factory during the week of
[Date], you have een granted this
license to practice kaizen daily in
accordance with the principles of
!ust in "i#e, $uality in %tation,
&roduction leveling, and &roduction
&reparation'
;N,2+ /: R+-&6&+')<
E=6&4,)&/' D,)+> ;1 1+,4 :4/2 ?,)+ /: &%%8,'-+<
@/*' D/+
P0,') M,',(+4
@/*' D/+
K,&.+' P4/2/)&/' L+,?+4
@/*' D/+
C/'%80),')
K,&.+' L&-+'%+