Overview of Forms and Meetings

Form\Meeting

Explanation

Prep Sheet:

The Prep Sheet is to be sent to the Supervisor of FF Manager of the

area one week in advance of the Event. The areas required to be
filled out should be highlighted.

Target Sheet Mtg

The Target Sheet meeting is to include the Continuous Improvement

Manager, Supervisor\FF Manager, and whoever else may be helping
lead the Event.
The purpose is to review the Prep Sheet and fill out the Target
Sheet. In addition to completing the Prep Sheet, a walk thru of
the line is to be conducted. Meetings with the production team
should be schedule to review what will happen during the Event.

Pre-Leaders Mtg

The Pre-Leaders meeting is to include the same people as the Target

Sheet Mtg.
The purpose is to review the final Target Sheet, review the hourly
Schedule of the Event, review the expectations of the Leaders
Meetings, and review the requirements for the Presentation.

All other listed forms All other forms are to be used as indicated in the training manual.
Post Leaders Mtg

This meeting is for the Continuous Improvement Manager and the Leaders
to determine what items will be tracked for cost reasons and input into

Overview of Forms and Meetings

Time

Form\Meeting

Explanation

5 days prior

Prep Sheet:

The Prep Sheet

area one week in advance of the Event. The areas required to be
filled out should be highlighted.

3 days prior

Target Sheet Mtg

The Target Sheet meeting is to include the Continuous Improvement

Manager, Supervisor\FF Manager, and whoever else may be helping
lead the Event.

1 day prior

Pre-Leaders Mtg

The Pre-Leaders meeting is to include the same people as the

Sheet Mtg.

During Event

All other listed forms All other forms are to be used as indicated in the training manual.

After the Event

Post Leaders Mtg

This meeting is for the Continuous Improvement Manager and the Leaders
to determine what items will be tracked for cost reasons and input into
the ZBT database.

Overview of Forms and Meetings

Time

Form\Meeting

Explanation

5 days prior

Prep Sheet:

The Prep Sheet is to be sent to the Supervisor of FF Manager of the

area one week in advance of the Event. The areas required to be
filled out should be highlighted.

3 days prior

Target Sheet Mtg

The Target Sheet meeting is to include the Continuous Improvement

Manager, Supervisor\FF Manager, and whoever else may be helping
lead the Event.
The purpose is to review the Prep Sheet and fill out the
Sheet. In addition to completing the Prep Sheet, a walk thru of
the line is to be conducted. Meetings with the production team
should be schedule to review what will happen during the Event.

1 day prior

Pre-Leaders Mtg

The Pre-Leaders meeting is to include the same people as the

Sheet Mtg.
The purpose is to review the final Target Sheet, review the hourly
Schedule of the Event, review the expectations of the
Meetings, and review the requirements for the Presentation.

During Event

All other listed forms All other forms are to be used as indicated in the training manual.

After the Event

Post Leaders Mtg

This meeting is for the Continuous Improvement Manager and the Leaders
to determine what items will be tracked for cost reasons and input into
the ZBT database.

Overview of Forms and Meetings

Time

Form\Meeting

Explanation

5 days prior

Prep Sheet:

The Prep Sheet

area one week in advance of the Event. The areas required to be
filled out should be highlighted.

3 days prior

Target Sheet Mtg

The Target Sheet meeting is to include the Continuous Improvement

Manager, Supervisor\FF Manager, and whoever else may be helping
lead the Event.

1 day prior

Pre-Leaders Mtg

The Pre-Leaders meeting is to include the same people as the

Sheet Mtg.

During Event

All other listed forms All other forms are to be used as indicated in the training manual.

After the Event

Post Leaders Mtg

This meeting is for the Continuous Improvement Manager and the Leaders
to determine what items will be tracked for cost reasons and input into
the ZBT database.

Overview of Forms and Meetings

Time

Form\Meeting

Explanation

5 days prior

Prep Sheet:

The Prep Sheet is to be sent to the Supervisor of FF Manager of the

area one week in advance of the Event. The areas required to be
filled out should be highlighted.

3 days prior

Target Sheet Mtg

The Target Sheet meeting is to include the Continuous Improvement

Manager, Supervisor\FF Manager, and whoever else may be helping
lead the Event.
The purpose is to review the Prep Sheet and fill out the Target
Sheet. In addition to completing the Prep Sheet, a walk thru of
the line is to be conducted. Meetings with the production team
should be schedule to review what will happen during the Event.

1 day prior

Pre-Leaders Mtg

The Pre-Leaders meeting is to include the same people as the Target

Sheet Mtg.
The purpose is to review the final Target Sheet, review the hourly
Schedule of the Event, review the expectations of the Leaders
Meetings, and review the requirements for the Presentation.

During Event

All other listed forms All other forms are to be used as indicated in the training manual.

After the Event

Post Leaders Mtg

This meeting is for the Continuous Improvement Manager and the Leaders
to determine what items will be tracked for cost reasons and input into
the ZBT database.

KAIZEN PREP-SHEET
Scope:
Line/area requested

Date(s)/shift

Requested by

Kaizen Coordinator

Goals:
Current situation & broad goals and objectives:

Things that the production team wants improved:

Team Membership:
(FF Mgr)

(1st Shift Oper)

(ME)

(2nd Shift Oper)

(QE)

(3rd Shift Oper)

(TL's)

(Maint)

(Mat'l Handler)

Support:
(Op's Mgr)

Data: Data needed & people responsible for obtaining that information prior to the event
Line layout w/mat'l flow

Build Consistency data

Efficiency reports

Weekly projected volume

Scrap reports/pareto

Production Schedule

Safety incidents

Pareto of quality issues

Pareto of down time issues

Team size(by shift)

Operator Instructions

Pre-meetings:
Goal meeting to review Prep Sheet and prepare Target Sheet
Conduct a line review
Pre-Leaders Meeting
Pre-meeting with production teams(15min) 1st
2nd

3rd

Target Sheet
Date:
Area:

Takt Time:

Kaizen Event

Current

Space (sqft)
Inventory(Raw\F.G.)
Walk distance (ft)
Parts Traffic dist (ft)
Cycle Time (sec)
Through-put
Team Size

1st
2nd
3rd

Productivity
Changeover (min)
5s(Poor/good/work class)
Standard Work
Pull One(Std WIP)
Scrap

Remarks:

Target

1st Day

2nd Day 3rd Day

Follow-up Audit

%
Change

#1

#2

30 Days

Date:______.

Date:______

Date:______

%
Change

Schedule of the Event

Day 1 "Document Reality and Elimination Waste
7:30
10:30
12:00
12:30
1:00
3:00
4:00
4:30

(7:00 if Tuesday)Introductions & Training

Line Observations for Waste
Lunch\Team Updates
Prioritize Waste
Implement Waste elimination on line
Rally teams to get progress & refocus on tasks for next few hours
Leader's Meeting
Continue waste elimination

Day 2 "Rebalance Value-Added Work\Verify Progress"

7:00
8:00
9:30
11:00
12:00
12:30
3:00
4:00
4:30

Takt Time Calculation & Line Balance training

Time Observations
Review Cycle Time Bar Charts and brainstorm line changes
Go and Make it Happen!
Lunch\Team Updates
Continue implementing changes(utilize production teams lunch time)
Rally teams to get progress & refocus on tasks for next few hours
Leader's Meeting
Continue to implement improvements

Day 3 "Standardize"
7:00 Standard Work Training
8:00 Tweak line changes
9:30 Implement Work Standardization & Update ODS

11:00
12:00
12:30
TBD

Presentation Preparation
Lunch
Dry Run Presentation
Plant Presentation

Leaders Meeting
Purpose:
1 Report on Kaizen activities at the plant.
2 Get further instructions on Target Sheet.
People:
1 Leader and Sub-Leader must be present from each Kaizen event
2 Facilitator\Sensai present
3 All attending are required to stay for the entire meeting
Format:
1 Each team will be given 10 minutes to present current status
2 Presentation are to be done by overhead projector
Contents:
Day 1:

Document Reality & Begin Change

1
2
3
4
5

Target Sheet with Target, Goals, 1st Day Status

Standard Work Sheet Before Kaizen showing mat'l and operator flow
Three Kaizen Change Sheets
Kaizen Newspaper with today's accomplishments
Kaizen Newspaper with tomorrow's Goals

4:00 * Leaders meeting

Day 2:

Implement Change & Begin Checking Results

1
2
3
4
5
6

Target Sheet with updated progress

Time studies of each operator and their work
Cycle Time Bar Chart Vs. Takt Time
Kaizen Newspaper with today's accomplishments
Three Kaizen Change Sheets
Kaizen Newspaper with tomorrow's Goals

4:00 * Leaders meeting

Day 3:

Finish Checking Results

1
2
3
4
5
6
7

Finalize Target Sheet with final results

Standard Work Sheet After Kaizen showing mat'l and operator flow
Cycle Time Bar Chart Vs. Takt Time After Kaizen
Updated Operator Instructions reflecting final changes
Kaizen Newspaper with total event accomplishments
Total of six Kaizen Change Sheets
Kaizen Newspaper with three future tasks to be completed in 30 days

9:30 * Review outline of presentation(see Presentation Format sheet)

12:00 Dry run of the Presentation with Kaizen Team

Note: Presentations will be at 2:30 on the last day!!!

Presentation Format
Purpose:
1 To develop a consistency in reporting improvements
People:
1 All participants will be present in the presentation
2 Team Leader to introduce team
Format:
1 Each team will be given 10 minutes to present
2 Presentation are to be done by overhead projector
3 Video to be played during presentation(if available)
Contents: Presentation contents and order
1 Team Leader introduces and explains the reason for the event.
'-Review the Target Sheet and Explain goals of the Event

2 The Co-Team Leaders use a Combination Sheet to

introduce Team Members and the time that they will be talking.

"Tell the Kaizen Story"

3 Show Std Worksheet BEFORE and AFTER the event.
-Ensure that you communicate to the audience that this is posted in the area.

4 Show Newspaper to display the items found and closed

5 Show Five Kaizen Change sheets as examples of the improvements
-Ensure that you display in the Change Sheet and communicate to the
audience that you have updated and trained to the new ODS standards.

6 Show the Cycle Time Bar chart BEFORE and AFTER the event.
7 Show Target sheet to indicate the percent improvements made
during the event.
8 Show Newspaper to display the three items left open for the area
to address within 30 days.

Kaizen Newspaper:________________________

# Wastes Found
# Wastes Eliminated

No.

Problem\Waste

Wastes:

Overproduction
Waiting Time
Transportation
Overprocessing
Inventory
Motion
Correction

Corrective Action

-Making more product than is required for this production cycle.

-Waiting for materials, toolings, job assignments, machine repairs, etc.
-Time lost by the direct labor operator while moving material to and from the work area.
-Extra steps in the process that can be eliminated.
-Too much inventory of raw materials, in process materials and finished product.
-Motion that does not add value.
-Reworked or scrapped product.

Who

By When

Process Name:

Standard Work Sheet

Date:

Model Name:
Scope of Operation

From:

Quality Check

To:

Safety Precaution

Standard WIP

Takt Time

Net Time

Process for
Observation:

Time Observations Form

Date:
Operator:

Compentent Task
No. From:
To:

Time for 1 cycle

10

Task time

Points of observed

Cycle Time Bar Chart Vs. Takt Time

Standard Work
Combination Sheet

Process for
Observation

Date:

Shift Goal:

Manual

FF:

Takt Time:

Automatic
Walk

Time
No. Operation Name

Totals

Dist

Man Auto Walk Walked

Operation Time (In Seconds)

2

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

46

48

50

52

54

56

58

60

Kaizen Changes

Problem\Waste

Before
Before Kaizen
Kaizen

Measures Taken

Results

After Kaizen