Supplier Development Kaizen Implementation Kit Rev. 3

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 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 TAKT TIME 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

OPERATIONS BALANCE CHART 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 SET UP REDUCTION 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 5S AUDIT 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 KAIZEN NEWSPAPER 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 INBRIEF PRESENTATION 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.