Forms to support Kaizen and other quality improvement programs

1. Kaizen – Forms & Checklists Forms to support Kaizen and other quality improvement programs Anand Subramaniam

2. 2 “Make everything as simple as possible, but not simpler." - Albert Einstein

3. 3 Highlights Kaizen – Overview Kaizen – Forms, Checklists

4. Kaizen – Overview

5. 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. 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

7. 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. 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

9. 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

10. Kaizen – Checklist / Forms

12. Identify problems

13. Set targets and enter on Target Progress Report

14. Plan & initiate Kaizen Workshop

15. Pair up 2 for each process

16. One times w/ stopwatch, other jots down times

17. Verify if Cycle Time meets TaktTime

18. Observe site

19. Identify Process

20. Prepare StandardisedWork Sheet

21. If equipment seems to lack in capacity, use Capacity Sheet to define problems

22. Fill out StandardisedWork Combination Sheet with best times

23. Note long times on Combination Sheet, there are opportunities for Kaizen

24. Continue to observe site, note problems on Kaizen Newspaper

25. Try out ideas for kaizen immediately, verify results

26. Prepare Kaizen Proposal Sheets for effective kaizen ideas

27. Update Kaizen newspaper

28. Update Target Progress Report

30. Kaizen Workshop Target Sheet 13

31. 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 /

32. 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

33. Task / Process -Time Observation 16

34. Waste Identification 17

35. 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:

36. 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

37. 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 １ Subtotal NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column. Total

38. Kaizen – Proposal Sheet 21 Location Objective Date Operator Before After Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

39. Kaizen Newspaper 22 DATE: _______/_______/_______/___________ TEAM: __________________________________ No. PROBLEM WHO BY WHEN CHECK

40. 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

41. Forms – Stakeholders & Change

42. Key Performance Measures 25

43. Inventory / Facility Audit 26

44. Outside Support Required 27

45. Communication Plan 28

46. 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

47. 30 “A mathematician is a device for turning coffee into theorems.” - Paul Erdos

48. 31 Good Luck http://www.linkedin.com/in/anandsubramaniam