BASIC

BASIC KAIZEN
KAIZEN
TOOLS
TOOLS
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
6.
7.
7.
8.
8.
9.
9.

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

Using
Using the
the Basic
Basic
Kaizen
Kaizen Tools
Tools
1
1

3
3

2
2

Calculate Takt Time.

Calculate Takt Time.
Identify problems.
Identify problems.
Set targets and enter on
Set targets and enter on
Target Progress Report
Target Progress Report
Plan & initiate Kaizen
Plan & initiate Kaizen
Workshop.
Workshop.

4
4

Observe site.
Observe site.
Identify Process.
Identify Process.
Prepare Standardized
Prepare Standardized
Work Sheet
Work Sheet

5
5

If equipment seems to
If equipment seems to
lack in capacity, use
lack in capacity, use
Capacity Sheet to define
Capacity Sheet to define
problems.
problems.
Fill out Standardized
Fill out Standardized
Work Combination Sheet
Work Combination Sheet
with best times.
with best times.

6
6

Note long times on

Note long times on
Combination Sheet, there are
Combination Sheet, there are
opportunities for Kaizen.
opportunities for Kaizen.
Continue to observe site,
Continue to observe site,
note problems on Kaizen
note problems on Kaizen
Newspaper
Newspaper

7
7

Update Kaizen newspaper.

Update Kaizen newspaper.
Update Target Progress
Update Target Progress
Report.
Report.

Pair up 2 for each process.

Pair up 2 for each process.
One times w/ stopwatch,
One times w/ stopwatch,
other jots down times.
other jots down times.
Find best times.
Find best times.
Verify if Cycle Time meets
Verify if Cycle Time meets
Takt Time.
Takt Time.

Try out ideas for kaizen

Try out ideas for kaizen
immediately, verify results.
immediately, verify results.
Prepare Kaizen Proposal
Prepare Kaizen Proposal
Sheets for effective kaizen
Sheets for effective kaizen
ideas.
ideas.

Kaizen
KaizenEVERY
EVERY
DAY!!.
DAY!!.

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

STANDARDIZED WORK SHEET

Process: __________________________
Part # ____________________________
Part Name: ________________________

Scope of
Operation

DATE: _____/____/____
Approvals:

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

Safety

Standard Work

Check

Precaution

In Process

BASIC
DATA

Total Pcs of Std

Takt

Cycle

Operators

Work in Process

Time

Time

this op/line total

sec.

1/

TIME OBSERVATION SHEET

Page _____ of _____

Date / Time: ___/____/____/_________________:________

Line / Process: __________________________________________________

Step

1
0

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Complete Cycle Time

10

Observed by: _____________________________________

11

12

13

14

15

Best Time

Observations (changeover time)

Cycle Time / Takt Time Bar Chart (Blank Chart)

Cycle Time
/ Takt Time Bar Chart

Cycle Time
1

4
8

Process

5
9

Cycle Time

1.2
1
0.8
0.6
0.4
0.2
0

Cycle Time / Takt Time

Bar Chart (with
Cycle Time / Takt Time Bar Chart
Graphing Feature)

Before
After

T/T

4
Process

Yamazumi (Stack) Chart (Blank Chart)

Yamazumi
(Stack) Chart

Cycle Time
1

4
8

Process

5
9

Yamazumi (Stack) Chart

(with Graphing Feature)
Yamazumi (Stack) Chart
Cycle Time

Task 1 Task 2 Task 3 Task 4 Task 5 Task 6

1
0.8
0.6
0.4
0.2
0

T/T

4
Process

Operator _____ of _____

Line: ____________________________
Process: _________________________

Step

Description

STANDARDIZED
WORK
COMBINATION
SHEET
Time

Man Auto Walk

Waiting

Totals

10

15

20

MANUAL:

Date: ______/______/_______

Quota / Shift: ____________

Section: __________________

Takt Time: ______________ sec.

AUTO:
WALKING:

TIME (unit: 1 sec.)

25

30

35

40

45

50

55

60

65

70

75

80

85

90

Page ____ of ____

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

Step

CAPACITY
SHEET
Description

Walking Time

Manual Time

Max Output

Part Name

Auto Run Time Completion Time

Current Output

Line
pieces

per Day

Pieces/Run

Change Time

Needed
Times:

Time/Piece

Capacity

Remarks

Subtotal

NOTE
Update times when improvements are achieved through kaizen, and detail reasons for improvement in Remarks column.

Total

pieces

Per Day
Workers

Tools

Base Times

Machine
ID

Part No.

Manual
Automatic
Walking

KAIZEN PROPOSAL SHEET

Location

Objective

Before

Problem

Date

Operator

After

Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

KAIZEN NEWSPAPER
DATE: _______/_______/_______/___________

TEAM: __________________________________
No.

PROBLEM

WHO

BY WHEN

CHECK

Kaizen License
[Name of Recipient]

John Doe
Plant Manager

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.

John Doe
Kaizen Promotion Leader

John Doe
Consultant

Expiration Date: [1 year from date of issuance]