Supplier Development
Kaizen Implementation Kit
Rev. 3
Kaizen Implementation Kit Summary
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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
Outbrief Presentation
Product Family
Identification Tools
Analysis and
Improvement Tools
Measures
Communication
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.
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.
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
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.
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.
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.
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.
MACHINE DOWNTIME
Identifies reasons and
frequency of machine
downtime and use this data to
find corrective actions
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.
KAIZEN PRINCIPLES
Used to assess a plant / factory /
company on its adherence to
Kaizen Principles that are key to
Lean implementation.
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.
OUTBRIEF PRESENTATION
Summarizes kaizen performance
improvements achieved during
event week and to identify future
actions needed to fully realize
event goals.