Supplier Development Kaizen Implementation Kit

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Supplier Development Kaizen Implementation Kit
Rev. 3
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Kaizen Implementation Kit Summary

• Kaizen Event Description
• Product Quantity Analysis
• Process Matrix
• Value Stream Map
• Takt Time
• Time Observations
• Operations and Operator Balance Charts
• Standard Work Combination Sheet
• Standard Work Sheet
• Capacity Study
• Setup Reduction
• Spaghetti Chart
• 5S Audit
• Machine Down Time
• Target Matrix
• Kaizen Newspaper
• Kaizen Principles
• Daily Outbrief
• Inbrief Presentation

Product Family Identification Tools
Analysis and Improvement Tools
Measures
Communication
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KAIZEN EVENT DESCRIPTION
General overview of the Supplier Development
process of conducting a Kaizen event. It
includes an overview and description of the
pre-event, the kaizen event week and the post
event follow up.
Please read the Kaizen Event Description before
utilizing the Kaizen Kit tools and templates.
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PRODUCT QUANTITY ANALYSIS
Analyzes the relationship between products and
quantity (production output). This will help
evaluate the mix of products being produced.
PROCESS MATRIX
A Process Matrix will highlight which parts
should be processed together in a cell and which
parts should be reprocessed in order to match the
flow of other parts.
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VALUE STREAM MAP
Defines the flow of materials and information
required to bring a product or service to a
consumer and identify where there is waste in the
process and help find ways to eliminate that
waste.
TAKT TIME
Takt time is the pace of production required to
meet customer demand. Since takt time is defined
by the customer, it becomes a very important
number in a lean environment and drives all floor
shop decisions
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TIME OBSERVATION
Calculates the standard time to complete each
operation in a process. This time observation is
then used to balance the line to meet Takt time.
OPERATIONS BALANCE CHART
Identifies the capacity of operations,
opportunities for one piece flow, and the
location for placement of standard work in
process (SWIP) to maintain part flow. Identifies
operations that may be combined and operations
that do not meet TAKT time.
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STANDARD WORK COMBINATION SHEET
A form that visually charts the information from
a time sheet observation. It provides a guide
for the operator in the manufacturing of a part.
It is used to illustrate the best combination of
worker and machine.
STANDARD WORK SHEET
Graphically shows the pre-determined sequence of
tasks for the best way to get the job done in the
amount of time available (within takt time) while
ensuring the job is done right the first time,
every time.
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CAPACITY STUDY
Identifies process capacity limitations. This
provides the baseline for improvement, primarily
through waste reduction.
SET UP REDUCTION
Identifies waste, value add and tasks which may
be done simultaneously and/or while the
machine/process is in operation.
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SPAGHETTI CHART
Graphically illustrates the flow of product
through the factory in an effort to highlight
waste in the form of excess travel distance.
5S AUDIT
Calculates the 5S score for manufacturing and
office environments. Identifies the areas of
improvement.
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MACHINE DOWNTIME
Identifies reasons and frequency of machine
downtime and use this data to find corrective
actions
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TARGET MATRIX
Identifies specific improvement targets during
pre-Kaizen activities and track progress toward
meeting the targets during the Kaizen event.
KAIZEN NEWSPAPER
Captures all the action items during a Kaizen
event, assigns a person responsible to complete
the open action item and sets target dates.
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KAIZEN PRINCIPLES
Used to assess a plant / factory / company on its
adherence to Kaizen Principles that are key to
Lean implementation.
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DAILY OUTBRIEF
Shares daily successes and challenges with other
groups and management during the pre-event and
event.
INBRIEF PRESENTATION
Informs management, the Sensei and new team
members of the opportunities identified during
pre-event week and to establish the event week
goals.
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OUTBRIEF PRESENTATION
Summarizes kaizen performance improvements
achieved during event week and to identify
future actions needed to fully realize event
goals.