Kaizen Tools and Templates

Kaizen Training

6 Step Approach

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

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C1

C2C4

C3

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C4.

A1.

STOPPING THE BLAME GAME

Focus on problem itself, not who caused it

2

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


Problem title:

Owner: Team:


Current outcome: Target outcome:Current outcome:

What is excluded from the solution

Target outcome:

4

from the solution space:


Conclusion from

Owner: Team:

Problem title:

Conclusion from quantification analysis:

5

NVA time _____________________________________________

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

6

Maintenance interval too long! the problem


Owner: Team:

Problem title:

Man Machine-

-

NVA time

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Method Material


Owner: Team:

Problem title:

Conclusion from ranking:

% of NVAtime caused

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Cause GCause FCause ECause DCause CCause BCause A

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

9

A lot of dust created Apply tool using air

Develop tools for exclusive use

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

10

A lot of dust created Apply tool using air

Develop tools for exclusive use

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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Owner: Team:

Problem title:


Cause A Solution A1

Cause B

Solution A2 Solution A3

Solution B1 Solution B2 Solution B3

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Owner: Team:

Problem title: h


A1 A2A1

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Low

Effort

High


Owner: Team:

Problem title:

Solution title Brief description Expected impact

Required investment


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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

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

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

2

3Reduce number

Reduce number of samples per batch

+

+

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

4

number of tests

Reduce number of tests per samplex

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+5

Eliminate activities

Reduce number of independent tests

Reduce costs per

testing

Reduce quality

Reduce aspiration level

Install data base to automatically coordinate process changes

6

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?

Empty templatesEmpty templates

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Problem title:

Owner: Team:


Current outcome: Target outcome:Current outcome:

What is excluded from the solution

Target outcome:

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from the solution space:


Conclusion from

Owner: Team:

Problem title:

Conclusion from quantification analysis:

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_________ _____________________________________________


Owner: Team:

Problem title:

Man Machine-

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NVA time

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Method Material


Owner: Team:

Problem title:

Conclusion from ranking:

% of ________ caused

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Cause GCause FCause ECause DCause CCause BCause A


Owner: Team:

Problem title:


_____________ ______________ ______________ ______________

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Owner: Team:

Problem title: h


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Low

Effort

High


Owner: Team:

Problem title:

Solution title Brief description Expected impact

Required investment


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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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Documents

Kaizen Tools and Templates