Kaizen Forms

Kaizen Event Area Profile: Summary Sheet

Team # :
Event Description:

Event Dates:

Preliminary Objectives:

Team:

Production Requirements (Takt Time):

Facilitator:
Consultant:

Process Information:

Current Situation and Problems

Kaizen Event
Target Sheet

Date:
TAKT Time:

Key Measurement

Safety Issues
Quality Issues
Lead Time
Cycle time
Value Adding Time
Necessary, Not Value Adding
Not Necessary, Not Value Adding
On Time (Fill Rate or Backlog)
Economic Lead Time
# of Steps, # of Handoffs
Volume / Throughput
Full-time Equivalent Crew
Productivity
Work In Process
Inventory
Walking Distance (Ft)
Space (Sq Ft)
5S

Remarks

Start

Target

1st Day

2nd Day

3rd Day

4th Day

Last Day

Difference

% Change

Standard Work Sheet

Department
Head

Department
Supervisor

Scope of
Operations

From

Date Prepared
or Revised

To

Quality Check

Safety
Precaution

Standard Work # of Pieces of

in Process
Std WIP
TAKT Time Net Time

Operator
Number

TIME OBSERVATION FORM

Date & Time:
Observer:

Process for Observation:

Item
No.

Component Task

Time for 1 Cycle:

Page:___________ of:___________

10

Best Task
Time

Points Observed

Model No.
and Name
Work
Sequence
Step
No.
Operation Name

Total

Standard Work Combination Sheet

Date
Prepared

Time
Auto Walk

Pieces Automatic

Walking

TAKT Time

Dept.

Man

Manual

Volume
Per Shift

Operation Time ( In Seconds)

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

Percent Loading Chart

Team:

Date:
Display TAKT
time with a red
line

Time

Process:

Operators / Operations

Kaizen Newspaper
Team Number: _____________
Item
No.

Description of Problem

Date:

Counter Measure

Page:______

Person
Responsible

%
Complete

Due Date
25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

25%

100%

50%

75%

of:______

Date
Complete

PRODUCTION CONTROL CHART

Date:
HOUR

TOTALS

Dept./Cell:
PLANNED
UNITS

ACTUAL DIFFERENCE
UNITS

REASON

MGR

Date: __________

Kaizen Title:____________________

Team #: ____________

Description of Problem:

Before Kaizen

Remarks:

Improvement Idea
Completed By: __________________________
Description of steps taken:

After Kaizen

Results:

Kaizen Event Survey

Name (optional):_______________________________________________
Area:_________________________________________________
Date:_________________________________________________
TAKT = 5 minutes

1) What did you learn?

7) What would make it better?

2) Were the objectives clear?

Yes

No

3) Were the objectives important?

Yes

No

4) Were you prepared?

Yes

No

5) Was your team successful?

Yes

No

6) Did you have fun?

Yes

No

SETUP OBSERVATION ANALYSIS WORKSHEET

Machine #
Part & OP
Step
Time
# Cumulative
Task

Date:
Before

Class
Before

Amount of time

Category by Activity
Element / Task Description

Int/Ext

Move to
T

External

After
After

Reduced Eliminated

Category by Activity

Time

Totals
Activity Categories
F. Foresight A. Attachment S. Setting Conditions T. Trial Runs & Adjustments
# of Steps Moved to External

# of Steps Reduced

# of Steps Eliminated

Time Moved to External

Time Reduced

Time Eliminated

TOPICAREA:
PROCESS AT A GLANCE (QA)
DATE:

10

20

30

TAKT TIME:

40

50

BY:

60

70

STEP #
Material
Process
Sketch
DRAWING
of Parts as
they
Come
Toget her
Written
Description

Specifications

Gauge
Go / No Go

POKE YOKE

Machine

&
Settings
TIME
DATA