BASIC KAIZEN TOOLS

1. BASIC KAIZEN TOOLS TARGET PROGRESS REPORT STANDARDIZED WORK SHEET TIME OBSERVATION SHEET CYCLE TIME / TAKT TIME BAR CHART YAMAZUMI (STACK) CHART STANDARDIZED WORK COMBINATION SHEET CAPACITY SHEET KAIZEN PROPOSAL SHEET KAIZEN NEWSPAPER

2. Using the Basic Kaizen Tools 3 1 2 • Pair up 2 for each process. • One times w/ stopwatch, other jots down times. • Find best times. • Verify if Cycle Time meets Takt Time. • Calculate Takt Time. • Identify problems. • Set targets and enter on Target Progress Report • Plan & initiate Kaizen Workshop. • Observe site. • Identify Process. • Prepare Standardized Work Sheet 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 Sheet, there are opportunities for Kaizen. • Continue to observe site, note problems on Kaizen Newspaper • Try out ideas for kaizen immediately, verify results. • Prepare Kaizen Proposal Sheets for effective kaizen ideas. 7  • Update Kaizen newspaper. • Update Target Progress Report. • Kaizen EVERY DAY!!.

3. 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:

4. STANDARDIZED WORK SHEET DATE: _____/____/____ Approvals: Process: __________________________ Part # ____________________________ Part Name: ________________________ Scope of Operation FROM: TO: SYMBOLS Quality Check Safety Precaution Standard Work In Process Total Pcs of Std Work in Process Takt Time Cycle Time Operators this op/line total NOTE: Takt Time, Work Sequence (same as numbers in “Step” column on Combination Sheet), and numbers of Standard Work in Process must be known to define Standardized Work. Identify all safety concerns, points where quality must be verified (go/no-go) and numbers of pieces of standard work in process using the symbols to the right. BASIC DATA sec. 1 /

5. TIME OBSERVATION SHEET Page _____ of _____ Date / Time: ___/____/____/_________________:________ Observed by: _____________________________________ Line / Process: __________________________________________________ # Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Best Time Observations (changeover time) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Complete Cycle Time

6. Cycle Time 1 2 3 4 5 6 7 8 9 Process Cycle Time / Takt Time Bar Chart Cycle Time / Takt Time Bar Chart (Blank Chart)

7. T/T Cycle Time / Takt Time Bar Chart (with Graphing Feature)

8. Cycle Time 1 2 3 4 5 6 7 8 9 Process Yamazumi (Stack) Chart Yamazumi (Stack) Chart (Blank Chart)

9. T/T Yamazumi (Stack) Chart (with Graphing Feature)

10. STANDARDIZED WORK COMBINATION SHEET Operator _____ of _____ Line: ____________________________ Date: ______/______/_______ Quota / Shift: ____________ MANUAL: AUTO: WALKING: Process: _________________________ Section: __________________ Takt Time: ______________ sec. Step Description Time TIME (unit: 1 sec.) Man Auto Walk 65 70 75 80 85 90 5 10 15 20 25 30 35 40 45 50 55 60 1 Totals Waiting

11. CAPACITY SHEET Page ____ of ____ New / Revised as of (date): ___/___/___ Part No. Line Current Output Per Day pieces Authorizations: Part Name Max Output per Day pieces Workers Needed Times: Manual Automatic Walking Step Description Machine ID Tools Capacity Remarks Base Times Walking Time Manual Time Auto Run Time Completion Time Pieces/Run Change Time Time/Piece １ Subtotal NOTE Update times when improvements are achieved through kaizen, and detail reasons for improvement in “Remarks” column. Total

12. KAIZEN PROPOSAL SHEET Location Objective Date Operator Before After Problem Effects (cycle time / inventory / changeover time reduction,poka yoke etc.)

13. KAIZEN NEWSPAPER DATE: _______/_______/_______/___________ TEAM: __________________________________ No. PROBLEM WHO BY WHEN CHECK

14. Kaizen License [Name of Recipient] 改 善 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 with the principles of Just in Time, Quality in Station, Production leveling, and Production Preparation. John Doe Kaizen Promotion Leader John Doe Consultant John Doe Plant Manager Expiration Date: [1 year from date of issuance]