kaizen tools and templates
DESCRIPTION
kaizenTRANSCRIPT
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Kaizen Training
6 Step Approach
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1a. PROBLEM DEFINITION
Problem title:
Description of problem to solve:
Owner: Team:
1b. QUANTIFICATION OF PROBLEM
Conclusion from quantification analysis: Solving issue 1 would address X% of non-productive time
Owner: Team:
Problem title:
KAIZEN IS A STRUCTURED AND PROVEN PROBLEM SOLVING APPROACH WORKING EVERYWHERE
Current outcome:
What is excluded from the solution space:
Target outcome:
Issue 3Issue 2 Issue 5Issue 1 Issue 4Non-productive time
Define problem and objectives1
2a. ROOT CAUSE ANALYSIS THE FISHBONE
Man Machine
Owner: Team:
Problem title:
2b. RANKING OF CAUSES
Conclusion from ranking: Addressing causes A, B, C would solve X% of the issue
Owner: Team:
Problem title:
5. PROGRESS UPDATE
Owner: Team:
Problem title:
Action Status
Solution A2:A ti A2 1
Main highlights since last review
Period:
Main challenges
e e p ob e a d object es
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Analyze the facts
1
5 Implement
6 Check and make sustainable
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Environment
Method Material Cause CCause B Cause GCause FCause E
% of inefficiency caused
Cause DCause A
Action A2.1: Action A2.2:
Solution B1: Action B1.1: Action B1.2:
Generate potential solutions2003
M M
MM
3a. IDENTIFICATION OF SOLUTIONS
Root cause Possible solutions (title and brief description)
Owner: Team:
Cause A
Cause B
Cause C
Solution A1 Solution A2 Solution A3
Solution B1 Solution B2
Solution C1 Solution C2 Solution C3 Solution C4
Problem title: 4. IMPLEMENTATION PLAN
Action
Owner: Team:
Problem title:
Responsible Start date End date Completed?
Solution A2: Action A2.1: Action A2.2:
Solution B1: Action B1.1: Action B1.2:
Name Name
NameName
DateDate
Date Date
Date Date
Date Date
3Generate potential solutions
4 Plan
Get approval
3d. APPROVALS PLAN
Who needs to approve
Owner: Team:
Who is responsible for getting the approvalBy when
Approval received
Igor Boevski John Smith16 June 2007
Problem title:
3b. PRIORITISATION OF SOLUTIONS
Do it soon Plan Legend (explanation of symbols)
A1:
Owner: Team:
Problem title:
3c. SOLUTIONS APPROVAL TEMPLATE
Solution title
Owner: Team:
Brief description Expected impact
Required investment
Time until capturing impact
D
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B1.
A2.
B2.
C2.
Problem title:
1Low
Effort
High
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Do if there is time Skip
A2: A3: B1: B2: C1: C2: C3: C4:
A1
B2
A3
B1
A2
C1
C2C4
C3
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C4.
A1.
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STOPPING THE BLAME GAME
Focus on problem itself, not who caused it
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1 PROBLEM DEFINITION
Statement: Non Value Added time is 40%
Bad Example: p
Reduce the non value added time
Good Example:
Reduce the non value added time due to walking from 2 hours per shift to 0,5 hours per shift within one month
KEY CRITERIAS- Describe problem specificly- Give Target
Gi e deadline
3
- Give deadline
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1a. PROBLEM DEFINITION
Problem title:
Owner: Team:
Description of problem to solve:
Current outcome: Target outcome:Current outcome:
What is excluded from the solution
Target outcome:
4
from the solution space:
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1b. QUANTIFICATION OF PROBLEM
Conclusion from
Owner: Team:
Problem title:
Conclusion from quantification analysis:
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NVA time _____________________________________________
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ROOT CAUSE ANALYSIS WITH THE 5 WHYs
1. Why did the machine stop? Bearing is overheated!
2. Why is the bearing overheated? Has too little oil!
Man
3. Why too little oil? Pump doesnt supply enough oil!
4. Why doesnt the pump supply enough oil? The filter is fouled!enough oil? The filter is fouled!
5. Why is the filter fouled? Maintenance interval too long!
Root cause ofth bl
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Maintenance interval too long! the problem
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2a. ROOT CAUSE ANALYSIS THE FISHBONE
Owner: Team:
Problem title:
Man Machine-
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NVA time
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Method Material
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2b. RANKING OF CAUSES
Owner: Team:
Problem title:
Conclusion from ranking:
% of NVAtime caused
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Cause GCause FCause ECause DCause CCause BCause A
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3 SOLUTION DEVELOPMENT Speed fast / impact highSpeed slow / impact low
Man
Problem Primary cause Fifth cause
Inspection criteria is inconsistent among
High variation of criteria in determining
CountermeasuresSpeed of implementation Impact
Excessive time for cleaning to remove rusts
inspectors
Lack of ant-rust
the occurrence of rust
Lack of approved sample to be compared or applied
Anti moisture indoor
Manufacture samples and approve
Machine facilities on the shop floor
Cleaning brush is easily broken.
Anti-moisture indoor shop
Material is not flexible and easily erodable
Use elastic and anti-erodable material
Material A lot of holes and thick T/S Carbon material is exposed
Tool is not suitable. The drill for manual work is revamped
Close holes when cleaned up
Rust may easily reoccur
Method Rust can not be removed manuallyLack of automatic tool for exclusive use
Contact with water when removing oil
Change chemicals use in removing oil
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A lot of dust created Apply tool using air
Develop tools for exclusive use
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3 SOLUTION DEVELOPMENT Speed fast / impact highSpeed slow / impact low
If you do a good root cause 1
Man
Problem Primary cause Fifth cause
Inspection criteria is inconsistent among
High variation of criteria in determining
CountermeasuresSpeed of implementation Impact
analysis, then you can easily develop solutions
Excessive time for cleaning to remove rusts
inspectors
Lack of ant-rust
the occurrence of rust
Lack of approved sample to be compared or applied
Anti moisture indoor
Manufacture samples and approve
Machine facilities on the shop floor
Cleaning brush is easily broken.
Anti-moisture indoor shop
Material is not flexible and easily erodable
Use elastic and anti-erodable materialPrioritize the solutions
b d i t d2
Material A lot of holes and thick T/S Carbon material is exposed
Tool is not suitable. The drill for manual work is revamped
Close holes when cleaned up
based on impact and easiness
Rust may easily reoccur
Method Rust can not be removed manuallyLack of automatic tool for exclusive use
Contact with water when removing oil
Change chemicals use in removing oil
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A lot of dust created Apply tool using air
Develop tools for exclusive use
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THINK LONG TERM
Implementing a Band-Aid A Band-Aid is a temporary solution, to contain a problem A countermeasure must address the root cause!A countermeasure must address the root cause!
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3a. IDENTIFICATION OF SOLUTIONS
Owner: Team:
Problem title:
Root cause Possible solutions (title and brief description)
Cause A Solution A1
Cause B
Solution A2 Solution A3
Solution B1 Solution B2 Solution B3
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3b. PRIORITISATION OF SOLUTIONS
Owner: Team:
Problem title: h
Do it soon Plan Legend (explanation of symbols)
A1 A2A1
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Low
Effort
High
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3c. SOLUTIONS APPROVAL TEMPLATE
Owner: Team:
Problem title:
Solution title Brief description Expected impact
Required investment
Time until capturing impact
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3d. APPROVALS PLAN
Owner: Team:
Problem title:
Who needs to approveWho is responsible for getting the approvalBy when
Approval receivedpp g g ppy
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4. PLAN WITH APPROVAL
Action RESPONSIBLEDEADLINEApproval received
1 2
Order new pipe Maintenance Engineer16 Feb 2008
Train new operator 10 Feb 2008 Supervisor
Review SOP 12 Feb 2008 Team with Prod. Mgr.
Approved by
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Igor Boevski
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4. IMPLEMENTATION PLAN
Owner: Team:
Problem title:
Action Responsible Start date End date Completed?
A i A1 1 N D DAction A1.1 Name Date Date Action A1.2 Name Date Date
Action B1.1 Action B1.2
Approved by
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Igor Boevski
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STEP 5: IMPLEMENT THE SOLUTIONSTEP 6: SUSTAIN
SUSTAINIMPLEMENT
TELLTRAINMONITORCHECK
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5. PROGRESS UPDATE
Owner: Team:
Problem title:
Action Status Main highlights since last review
Period:
Main challengesg
Action A1.1
Action A1 2
Action B1.1
Action A1.2
Action B1 2Action B1.2
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Problem SolvingProblem Solving
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Trees should be mathematical correct EXAMPLE
QC tests for raw materials from other Company sites
Examples
Avoid double testing
1
QC
? What is wrong?
Use random sampling
Install automatic testing in production
Combine batches in onedelivery from supplierto one batch for sampling
Perform real-time measurement of selected
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3Reduce number
Reduce number of samples per batch
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testing in production
Reduce number of repeats
R d b f
Reduce costs of testing
parameters
Establish robustness oftest to eliminate double-testing of samples
Reduce aspiration level
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number of tests
Reduce number of tests per samplex
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Eliminate activities
Reduce number of independent tests
Reduce costs per
testing
Reduce quality
Reduce aspiration level
Install data base to automatically coordinate process changes
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samplex
?Increase efficiency
Eliminate activities
costs per test
R d t f
Reduce quality control cost Replace newer technology
Transfer test results electronically to external
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+ ?
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Increase efficiency
Reduce costs of supporting tasks
yparties
Create order database for tests outside regular supply chain (e.g., R&D)
9?
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Empty templatesEmpty templates
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1a. PROBLEM DEFINITION
Problem title:
Owner: Team:
Description of problem to solve:
Current outcome: Target outcome:Current outcome:
What is excluded from the solution
Target outcome:
23
from the solution space:
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1b. QUANTIFICATION OF PROBLEM
Conclusion from
Owner: Team:
Problem title:
Conclusion from quantification analysis:
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_________ _____________________________________________
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2a. ROOT CAUSE ANALYSIS THE FISHBONE
Owner: Team:
Problem title:
Man Machine-
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NVA time
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Method Material
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2b. RANKING OF CAUSES
Owner: Team:
Problem title:
Conclusion from ranking:
% of ________ caused
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Cause GCause FCause ECause DCause CCause BCause A
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3a. IDENTIFICATION OF SOLUTIONS
Owner: Team:
Problem title:
Root cause Possible solutions (title and brief description)
_____________ ______________ ______________ ______________
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3b. PRIORITISATION OF SOLUTIONS
Owner: Team:
Problem title: h
Do it soon Plan Legend (explanation of symbols)
a
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H
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h
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Do if there is time Skip
L
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Low
Effort
High
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3c. SOLUTIONS APPROVAL TEMPLATE
Owner: Team:
Problem title:
Solution title Brief description Expected impact
Required investment
Time until capturing impact
n
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3d. APPROVALS PLAN
Owner: Team:
Problem title:
Who needs to approveWho is responsible for getting the approvalBy when
Approval receivedpp g g ppy
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4. IMPLEMENTATION PLAN
Owner: Team:
Problem title:
Action Responsible Start date End date Completed?
____________ _______ _______ ______
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5. PROGRESS UPDATE
Owner: Team:
Problem title:
Action Status Main highlights since last review
Period:
Main challengesg
_________
_________
_________
_________
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