Kaizen

1. FORMS Kaizen SMED Forms

2. WASTE ANALYSIS Team: Event: Date: Location:

3. OPPORTUNITY SELECTOR IMPLEMENTATION REF No Opportunity Ref No Opportunity Ref Team: Event: Date: Location:

4. ACTION CHART Team: Event: Page of Date: Date: Location:

5. ACTION CHART Team: Event: Page of Date: Date: Location:

6. SPAGHETTI DIAGRAM Team: Process: Date: Location:

7. OPERATIONAL SEQUENCE CHART Process: Team: Date: Location: Operation:

8. SMEDSET-UP TIMES Part: Team: Tool: Date: M/C:

9. TOTAL PRODUCTIVE EFFECTIVENESS X Performance Rate: (Minor stops & idling, Speed loss) Standard Time x Units made = Performance Rate % = Operating Time X Quality Rate: (Scrap & rework) Parts Count - Defects = Quality Rate % = Parts Count = TPE % = Process: Team: Date: Location: Availability Rate: (Equipment failure, Set-up & adjustment, Tool change, Start-up) Available Time - Down Time = Availability Rate % = Available M/C Time Alternatives: Performance Rate = (Op Time - Perf. loss)/OpT Quality Rate = (Productive time - Defect time)/Prod Time

10. TPE OBSERVATION Perform. Loss Scrap/Rework Quality Loss Equip Failure Set-up/adjust Tool Change Start-up loss Avail. Loss Stops/Idling Speed loss Run Time Start End Equip.: Name: Date: Part: Remarks

11. Effectiveness Improvement Sheet Date: Machine: Department: Improvement Dates Improvement Eater Problem Description and suggested improvement Measurement Job begins on the Time Before Break- downs, Start-up Job ends on the Time After Job begins on the Time Before Tool Change Job ends on the Time After Job begins on the Time Before Set-up & Adjustment Job ends on the Time After Job begins on the Time Before Idling, minor stoppages and speed loss Job ends on the Time After Job begins on the Time Before Scrap & Rework Job ends on the Time After Process owner Responsible for follow-up