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Kaizen – Forms & Checklists

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Forms to support Kaizen and other quality improvement programs

Forms to support Kaizen and other quality improvement programs

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Kaizen – Forms & Checklists Kaizen – Forms & Checklists Presentation Transcript

  • Kaizen – Forms & Checklists
    Forms to support Kaizen and other quality improvement programs
    Anand Subramaniam
  • 2
    “Make everything as simple as possible, but not simpler."
    - Albert Einstein
  • 3
    Highlights
    Kaizen – Overview
    Kaizen – Forms, Checklists
  • Kaizen – Overview
  • 5
    Why Kaizen Events?
    Kaizen drives the improvements which lead to a leaner business operating system
    Future State (Lean)
    (To~Be)
    Current State
    (As~Is)
    Kaizen
  • 6
    Do It Again
    Start Here
    Celebrate
    Document Reality
    Make this the Standard
    Identify Waste
    Kaizen
    Measure Results
    Plan Counter Measures
    Verify Change
    Reality Check
    Make Changes
    6
    Kaizen Cycle
  • Kaizen Event - Implementation
    Successful implementation of Kaizen Event, include –
    5-S
    8-W
    The 5 Whys
    Value Stream Mapping
    PDCA (Plan, Do, Check, Act)
    7
  • 8
    Lean - Tools
    5S
    7 W (Waste)
    Jidoka / Andon / PokaYoke / Mistake Proofing
    Single minute exchange of die (SMED)
    Standard Operating Proced-ures
    Kaizen Tools
    Kanban
    Total Preventa-tiveMainten-ance
    Takt time
    Through-put time
    Spaghetti diagram
    Value Stream Mapping
    Kaizen blitz or event
  • Kaizen Umbrella
    Quality Improvement
    Customer Orientation
    Total Quality Control
    Discipline in Work Place
    Productivity Improvement
    Total Productive Maintenance
    New Product Development
    Co-operative Labour Management Relations
    Kanban
    Robotics
    Zero Defect
    Q.C. Circle
    Automation
    Just-in–Time
    Suggestion System
    Small Group Activity
    9
  • Kaizen – Checklist / Forms
  • Kaizen Tools – When, Where, What..
    11
    • Calculate TaktTime
    • Identify problems
    • Set targets and enter on Target Progress Report
    • Plan & initiate Kaizen Workshop
    • Pair up 2 for each process
    • One times w/ stopwatch, other jots down times
    • Verify if Cycle Time meets TaktTime
    • Observe site
    • Identify Process
    • Prepare StandardisedWork Sheet
    • If equipment seems to lack in capacity, use Capacity Sheet to define problems
    • Fill out StandardisedWork 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
    • Try out ideas for kaizen immediately, verify results
    • Prepare Kaizen Proposal Sheets for effective kaizen ideas
    • Update Kaizen newspaper
    • Update Target Progress Report
    • Kaizen Every Day !!.
  • Kaizen Event Profile
    12
  • Kaizen Workshop Target Sheet
    13
  • Kaizen – Work Sheet
    14
    DATE: _____/____/____
    Approvals:
    Process: __________________________
    Part # ____________________________
    Part Name: ________________________
    Scope of Operation
    FROM:
    TO:
    SYMBOLS
    Takt
    Time
    Cycle
    Time
    Operators
    this op/line total
    Total Pcs of Std
    Work in Process
    Standard Work
    In Process
    Safety
    Precaution
    Quality
    Check
    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 StandardisedWork. 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.
    sec.
    1 /
  • Kaizen - Time Observation
    15
    Date / Time: ___/____/____/_________________:________
    Observed by: _____________________________________
    Line / Process: __________________________________________________
    #
    Step
    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    13
    14
    15
    Best Time
    Observations (changeover time)
    0
    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    13
    14
    15
    Complete Cycle Time
  • Task / Process -Time Observation
    16
  • Waste Identification
    17
  • Progress Report – Current vs. Target
    18
    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:
  • Standardised Work Sheet
    19
    Date: ______/______/_______
    Quota / Shift: ____________
    MANUAL:
    AUTO:
    WALKING:
    Process: _________________________
    Section: __________________
    Takt Time: ______________ sec.
    Step
    Description
    Time
    TIME (unit: 1 sec.)
    Line #_________________________
    Man
    Auto
    Walk
    65
    70
    75
    80
    85
    90
    5
    10
    15
    20
    25
    30
    35
    40
    45
    50
    55
    60
    1
    Waiting
    Totals
  • Kaizen - Capacity / Load Planning
    20
    Part No.
    Line
    Current Output
    Per Day
    pieces
    Authorisations:
    Part Name
    Max Output
    per Day
    pieces
    Workers
    Needed
    Times: Manual
    Automatic
    Walking
    Step
    Description
    Machine
    ID
    Tools
    Capacity
    Remarks
    Base Times
    Walking Time
    Manual Time
    Auto Run Time
    Completion Time
    Pieces/Run
    Change Time
    Time/Piece

    Subtotal
    NOTE
    Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.
    Total
  • Kaizen – Proposal Sheet
    21
    Location
    Objective
    Date
    Operator
    Before
    After
    Problem
    Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)
  • Kaizen Newspaper
    22
    DATE: _______/_______/_______/___________
    TEAM: __________________________________
    No.
    PROBLEM
    WHO
    BY WHEN
    CHECK
  • Standard Work Instruction Sheet
    23
    Revision Date Signature
    Standard Work Instruction Sheet
    Work Sequence
    Operation Name Operation Number
    Element
    1
    2
    3
    4
    5
    6
    7
    Critical Safety Char.
    Critical Quality
    Check
    Critical Quality Check
    Job Assists
    Tools Required
    Parts Required
    Job Assists
    Notes
  • Forms – Stakeholders & Change
  • Key Performance Measures
    25
  • Inventory / Facility Audit
    26
  • Outside Support Required
    27
  • Communication Plan
    28
  • Visual Management
    Checklists
    Skills Matrix
    Color coding
    Colored Lines
    Address Grids
    Kanban Cards
    Pictures / Graphics
    Signage—Directions / Instructions
    Labeling
    Scoreboards
    Signals (lights, horns)
    Defect Boards / Tables
    Sample Boards / Tables
    Area Information Boards
    Production Control Boards
    Suggestion Program
    29
  • 30
    “A mathematician is a device for turning coffee into theorems.”
    - Paul Erdos
  • 31
    Good Luck
    http://www.linkedin.com/in/anandsubramaniam