BASIC KAIZEN

TOOLS
1. TARGET PROGRESS REPORT
2. STANDARDIZED WORK SHEET
3. TIME OBSERVATION SHEET
4. CYCLE TIME / TAKT TIME BAR CHART
5. YAMAZUMI (STACK) CHART
6. STANDARDIZED WORK COMBINATION SHEET
7. CAPACITY SHEET
8. KAIZEN PROPOSAL SHEET
9. KAIZEN NEWSPAPER
 Using the Basic Kaizen
Tools
3
1 2

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

Identify problems. Observe site. One times w/ stopwatch, other jots
Set targets and enter on Target Identify Process. down times.
Progress Report Prepare Standardized Work Find best times.
Plan & initiate Kaizen Sheet Verify if Cycle Time meets Takt
Workshop. Time.

4
5 6

If equipment seems to lack in

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

7 

Update Kaizen newspaper.

Update 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

善
license to practice kaizen daily in accordance
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]