Kaizen

Workflow Forms
FORMS
 Event: Team:
WASTE ANALYSIS
Location: Date:
WASTE OBSERVED CAUSE

OVERPRODUCTION

WAITING

TRANSPORT

INEFFICENT PROCESS

INVENTORY

UNNECESSARY
MOVEMENTS

DEFECTS
 IMPLEMENTATION REF
Event: Team: EASY HARD
OPPORTUNITY SELECTOR HIGH A C
Location: Date: LOW B D

No Opportunity Ref No Opportunity Ref

 Event: Team:
ACTION CHART Page of
Location: Date:
N o . Co nc e rn D a te Co unte rme a s ure R e s p . Ta rg e t % Co mp le te Co mp le te Co nfirm OK
R a is e d D a te 25% 50% 75% 100% D a te D a te
 Event: Team:
ACTION CHART Page of
Location: Date:

No. Comment Measure Who When Prog.

 Process: Team:
SPAGHETTI DIAGRAM
Location: Date:
 Operation
Process: Team: Delay
BOX FLOW CHART Inspection
Storage
Location: Date: Transport

<----------------- DEPARTMENT/SECTION/AREA -------------->

 Operation
Process: Team: Delay
PROCESS FLOW CHART Inspection
Storage
Location: Date: Transport

No. OPERATION/PURPOSE FLOW DEPARTMENT AREA DIST TIME QUANTITY HUMAN HUMAN COMMENT
.O:D:I:S:T NAME M² M MIN No. DIST TIME

10

11

12

13

14

15

16

17

18

19

20
TOTALS
AREA DIST TIME QUANTITY HUM DIST HUM TIME
 Process: Team:
VALUE ADDED
Location: Date:
VALUE NON-VALUE VALUE NON-VALUE
No OPERATION No. OPERATION
ADDED ADDED ADDED ADDED

PROCESS TIMES SUB TOTALS PROCESS TIMES SUB TOTALS

PROCESS TIMES TOTALS
SUPPLY CHAIN Title: Team:

MANAGEMENT Date:

MY SUPPLIER MY PROCESS MY CUSTOMER

MIN MIN
QTY QTY

Supplier Takt time My Takt time Customer Takt time

Suppliers product My material My product Customers material

 Kanban   Kanban 

Type: Type:

Description: Description:
HUMAN WORK Area: Team:

CALCULATION Date:
For each part For each lot
A B C D E G H J
A
A * (B+C+D) G
H *
P/N Qty/yr  machine 1  walking  other 2 Total per part  set-up Batch Total set-up
(family) time time time (h/yr) time size (h/yr)

Total Total
 = total of... K L
hours/yr hours/yr
K+L n.working days / yr WORKING TIME 1: Operator's required working time when the machine is in operation
TOTAL PER TOTAL PER DAY 2: Includes the machine loading and unloading
YEAR
 STANDARD WORK IN Process: Team:

PROGRESS Date:
OP OP OP OP OP OP OP OP OP OP OP OP

Actual
Objective
Ideal
 Process:
STANDARD OPERATION
Location: Date:

QUALITY SAFETY STD IN PROCESS STATION CYCLE LEAD FLOOR

CHECK OPERATION STOCK TIME TIME TIME AREA
 Event: Team:
ERROR PROOFING
Location: Date:

CURRENT POKA YOKE AVOIDED ERRORS

POSSIBLE ERRORS POKA YOKE TO BE SET-UP

 No. Shifts
JOB DISTRIBUTION PILLAR Subject:
CHART Takt Time = working time / day
parts requirement / day
=
Date:

Operation
Operators
OPERATIONAL SEQUENCE Process: Team:

CHART Location: Date:

Operation:
 Title: Team:
PART/PROCESS MATRIX
Location: Date:
Machine
No

Process

Qty Part #

10
BASE OPERATIONAL Process: Team:

MEASURES Location: Date:

Delivery Efficiency: P:D Ratio:

Total Cycle Time = Production Lead-Time =
: :
Production Lead Time = Delivery Lead-Time =
= =
Delivery Efficiency = P:D Ratio =

Stock Quantities:
Raw Material =
TAKT Time:
Pre-Cell =
Daily Available Time =
: In Cell =
Daily Required Quantity = Out Cell =
= Post-Cell =
TAKT Time =
Sub-total =
Customer =
Total =