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
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
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