Kaizen Events “Results through Education” （3）
SetupReduction Kaizen
SetupReduction Kaizen
Event Preparation Checklist: Specific
Check box aftercompletion.
qGather the baseline statistical information from which to measureimprovement. The teams will verify thisdata when they start but it needs to be generated for each area in advance toallow them the maximum amount of time to work on improvements. This information should include:
o A layout of each area is to be done. This can be generated from the facilities diagram providing that it isnot too far out of date. This will beused to calculate the square footage dedicated to the area as well as thepath/distance for the changeover process.
qA list of the products that go through the area and the currentchangeover times. Available time for changeover and desired number ofchangeovers per shift.
qA standard operating procedure or description of the current processin as much detail as possible.
qWhile in the plant the teams will each need a small space tomeet. The space should be close to theirfocus area.
qArrange for priority maintenance support.
qReview the Value Stream Maps and target metrics.
qGet plant layout if available. If not, complete a Standard Work Sheet (SWS).
qGo to the plant. Walk,observe the assigned process.
qLocate and number each machine in the assigned process.
qGet the data and history for each machine including OEE.
qVerify the availability of subject matter experts, machineoperators, changeover operators, and process narrator.
qReview a video of the Changeovers if available.
SetupReduction Kaizen
Team Leader Checklist: Specific
Document The Current State:
qTalk to the area’semployees prior to doing the shop floor study. Overview the status of the project and discuss the approach andoutcomes.
qTime each step in the process and record it on a Time ObservationSheet (TOS). Remember to use a separate sheet for each operator or helper.
qVideo the changeover. (Video guidelines will be provided byProductivity.)
qComplete the eight steps of changeover documentation.
qComplete the “Effect Side” of the changeover documentation CEDACchart.
Determine opportunities for improvement:
qMeet with the area’s employees for a status report. Explain the current situation as documentedand the next steps you plan to take to reduce the changeover time. Get any additional facts and ideas from them. Explain that alternatives will be reviewedand that they will have an opportunity for input at the next phase prior toimplementation.
qBrainstorm ideas and follow the eight steps to changeoverimprovement.
qFill in the eight steps of changeover Improvement on the ChangeoverImprovement CEDAC chart.
qReview the results with the teams, process owners and managers.
qDevelop a milestone implementation action plan.
qCoordinate the resources required for implementation.
qFormalize the new Standard Process.
Setup Reduction Kaizen
Team Leader Checklist: Specific(continued)
Notify the proper resources for all immediate equipment or area changes.
qCreate a checklist to modify the equipment and/or area. This is forthose items that can be done immediately. A second checklist will be for thoseitems to be completed in a short time period. (target is three months or less).
qIf possible re-run the changeover after implementing the immediatechanges. Document the results.
qMake any additional refinements to the process.
qRedo the Time Observation Sheet to verify the actual with the plan.
qItemize all implemented improvements.
qDevelop the Kaizen Team Report using the Team Report Guidelines.
ContinuousImprovement Ideas
qDuring the Team Reports itemize all proposed ideas for improvementnot implemented. Categorize them intoshort term and long term ideas. Updatethe Value Stream Map and Lean Strategic Plans with the new data and cost benefitanalysis. Prepare an event summary with key metrics and learning’s.
Setup ReductionKaizen
Team Report Out Checklist
Format:
· Limit your formal presentationto 20 minutes plus 10 minutes for Q&A.
· Preferred media are flipcharts, overheads and handouts.
· Hand written or PC generateddocuments or both are OK.
· All Team Members must participate in the Report out.
Content:
q Area of Focus and Boundaries; Use the Current and Future State ValueStream Maps, Kaizen bursts and links to strategic metrics.
q Team Membership Review.
q Summary of activity.
q Before and After:
q Procedures for performing changeover.
q Photographs (as O/H’s or Handouts)
q Metrics:
§ Value Added Ratio
§ OEE
§ Capacity (Time/ Revenue $)
§ C/O time annually.
§ % Delta
q Review of Improvements Incorporated into new Process:
q Lead time
q Uptime
q Delivery/Schedule/ Flexibility
q Impact on OTD
q Safety
q Schedule for Standardization of revised procedure
q Schedule for achieving short term and three month target.
q Operator(s) flowchart.
q Changeover tracking documentation process.
q A list of remaining maintenance support issues.
q Recommendations to prevent regression or backsliding.
q Listing of future improvement opportunities.
q Issues / resources for Quickchange education process.
q Issues / resources for Quickchange implementation process.
Kanban Systems Kaizen
Kanban Systems Kaizen
Event Preparation Checklist: Specific
qDetermine the items to be placed under kanban control. Consider:
o Chronic Shortages
o Chronic Overages
o A-B-C analysis findings
o “Dead” Inventory Items
qMitigated the issue of Management expectations that inventory levelswill always decrease for those items placed under kanban control.
qPerform pre-event communications to all impacted.
qPerform necessary data collection (Relevant to both consuming andsupplying activities)
o Demand(s)/Volume(s)
o Capacity(s)
o Set-Up Times
o Lot Sizes
o Cycle Times
o Container Capacities
o Historical Variation
o Risks
o Other pertinent data
qVerified that accuracy of the above data.
qAre the necessary raw materials and supplies available.:
o Kanban Board
o Kanban Cards
o Bins
o Parts Presentation and Line Stock Racks (Textube)
o Fully stocked Kaizen Supply Shed
Kanban Systems Kaizen
Team Leader Checklist: Specific
NOTE:Meet with the operators in your assigned as soon as possible to overview theproject with them, answer questions, and ask for their help. Tell them that they will be kept current onyour activities and that they will be given an opportunity to give input andideas.
qReview and verify the data provided to you with your team members.
qLead the data collection process for any missing information yourteam needs.
qLead the calculation process with your team and resolve any issuethat are subjective in nature.
qLead the new process visioning/brainstorming step.
qDesign on paper the new process design ( a map). Be sure to indicate:
o Board positioning
o Bin and Line stock positioning
o Card and Product paths
o Etc.
qList the action items necessary to get the paper design to becomereality.
qLead the interim management report out.
qLead the execution of the identified action items.
qLead the creation of the new standard operating procedure.
qTest the new process and make any adjustments as necessary.
qTrain all necessary in the new SOP
qIdentify open action items and assign people responsible forclosure.
qLead the development of the final report out.
qLead the follow-up process regarding open action items.
Kanban Systems Kaizen
Team Report Out Checklist
Format:
· Limit your formal presentationto 20 minutes plus 10 minutes for Q&A.
· Preferred media are FlipCharts, Overheads and handouts.
· Hand written or PC generateddocuments or both are OK.
· All Team Members must participate in the Report out.
Content:
q Area of Focus and Boundaries
q Team Membership Review
q Summary of activity
q Before and After:
q Metrics
q Photographs (as O/H’s or Handouts)
q Review new process features
q Explanation of the mechanics of the new process
q Review of the new SOP
q Reflection: Key lesson learned during the week.
