BASIC

BASIC KAIZEN
KAIZEN
TOOLS
TOOLS
1.1. TARGET
TARGETPROGRESS
PROGRESSREPORT
REPORT
2.2. STANDARDIZED
STANDARDIZEDWORK
WORKSHEET
SHEET
3.3. TIME
TIMEOBSERVATION
OBSERVATIONSHEET
SHEET
4.4. CYCLE
CYCLETIME
TIME//TAKT
TAKTTIME
TIMEBAR
BARCHART
CHART
5.5. YAMAZUMI
YAMAZUMI(STACK)
(STACK)CHART
CHART
6.6. STANDARDIZED
STANDARDIZEDWORK
WORKCOMBINATION
COMBINATIONSHEET
SHEET
7.7. CAPACITY
CAPACITYSHEET
SHEET
8.8. KAIZEN
KAIZENPROPOSAL
PROPOSALSHEET
SHEET
9.9. KAIZEN
KAIZENNEWSPAPER
NEWSPAPER
 Using
Using the
the Basic
Basic Kaizen
Kaizen
Tools
Tools
3
1 2 3
1 2

Calculate Takt Time. Pair up 2 for each process.

Calculate Takt Time. Pair up 2 for each process.
One
Identify
Identifyproblems.
problems.
Observe site.
Observe site. Onetimes w/ stopwatch, other jots
times w/ stopwatch, other jots
Set down times.
Settargets and enter on Target Identify
targets and enter on Target IdentifyProcess.
Process. down times.
Find best times.
Progress Report Prepare
PrepareStandardized Work  Find best times.
Progress Report
Plan & initiate Kaizen Sheet
Standardized Work Verify
VerifyififCycle Time meets Takt
Cycle Time meets Takt
 Plan & initiate Kaizen Sheet Time.
Workshop. Time.
Workshop.

4
4 5
If equipment seems to lack in
If equipment seems to lack in
capacity, use Capacity Sheet to
capacity, use Capacity Sheet to
define problems.
define problems.
Fill out Standardized Work
 Fill out Standardized Work
Combination Sheet with best
Combination Sheet with best
times.
times.
5 6
Note long times on Combination
Note long times on Combination
Sheet, there are opportunities for
Sheet, there are opportunities for
Kaizen.
Kaizen.
Continue to observe site, note
 Continue to observe site, note
problems on Kaizen Newspaper
problems on Kaizen Newspaper
6
Try out ideas for kaizen
Try out ideas for kaizen
immediately, verify results.
immediately, verify results.
Prepare Kaizen Proposal Sheets
 Prepare Kaizen Proposal Sheets
for effective kaizen ideas.
for effective kaizen ideas.

7 
7 

Update Kaizen newspaper.

Update Kaizen newspaper. Kaizen EVERY DAY!!.
Update
UpdateTarget Progress Report.
Target Progress Report. Kaizen EVERY DAY!!.
 TARGET PROGRESS REPORT
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:
 STANDARDIZED WORK SHEET DATE: _____/____/____
Process: __________________________ Approvals:
Part # ____________________________ Scope of
FROM:
Operation
Part Name: ________________________ TO:

SYMBOLS Quality Safety Standard Work Total Pcs of Std Takt Cycle Operators
NOTE: Takt Time, Work Sequence (same as numbers in “Step” column on Co BASIC
Check Precaution In Process Work in Process Time Time this op/line total
mbination Sheet), and numbers of Standard Work in Process must be known t
o define Standardized Work. Identify all safety concerns, points where quality DATA
must be verified (go/no-go) and numbers of pieces of standard work in proces 1/
sec.
s using the symbols to the right.
 Page _____ of _____
TIME OBSERVATION SHEET
Date / Time: ___/____/____/_________________:________
Line / Process: __________________________________________________
Observed by: _____________________________________

# Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Best Time Observations (changeover time)

0
1

10

11

12

13

14

15

Complete Cycle Time

 Cycle Time / Takt Time Bar Chart
Cycle Time / Takt Time Bar Chart (Blank Chart)
Cycle Time

1 2 3 4 5 6 7 8 9
Process
 Cycle Time / Takt Time Bar
Chart (with
Cycle Graphing
Time / Takt Feature)
Time Bar Chart
1.2
1 T/T
0.8
0.6
0.4
Cycle Time

0.2
0
1 2 3 4 5 6 7
Before
After Process
 Yamazumi (Stack) Chart
Yamazumi (Stack) Chart (Blank Chart)
Cycle Time

1 2 3 4 5 6 7 8 9
Process
 Yamazumi (Stack) Chart (with
Graphing Feature)
Yamazumi (Stack) Chart
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6

1
0.8 T/T
0.6
0.4
0.2 Time
Cycle
0
1 2 3 4 5 6 7
Process
 Operator _____ of _____

Line: ____________________________ STANDARDIZED Date: ______/______/_______ Quota / Shift: ____________ MANUAL:

Process: _________________________ WORK COMBINATION AUTO:

Section: __________________ Takt Time: ______________ sec.
SHEET WALKING:

Time TIME (unit: 1 sec.)

Step Description
Man Auto Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

Waiting

Totals
 Page ____ of ____
　　 New / Revised as of (date): ___/___/___
Current Output
Authorizations: Part No. Line pieces
CAPACITY Part Name
Max Output
pieces
Per Day
Workers

SHEET Base Times Tools

per Day Needed
Times: Manual
Machine
Step Description Capacity Remarks Automatic
ID Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/Piece Walking

Subtotal NOTE
Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column.
Total
 KAIZEN PROPOSAL SHEET
Location Objective Date Operator

Before After

Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)
 KAIZEN NEWSPAPER
TEAM: __________________________________ DATE: _______/_______/_______/___________

No. PROBLEM WHO BY WHEN CHECK

 Kaizen License
[Name of Recipient]

改
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

善 with the principles of Just in Time, Quality in

Station, Production leveling, and Production
Preparation.

John Doe John Doe John Doe

Plant Manager Kaizen Promotion Leader Consultant

Expiration Date: [1 year from date of issuance]