Transcript CI CHARTS

Kaizen
Workflow Forms
FORMS
WASTE ANALYSIS
WASTE
OVERPRODUCTION
WAITING
TRANSPORT
INEFFICENT PROCESS
INVENTORY
UNNECESSARY
MOVEMENTS
DEFECTS
Event:
Team:
Location:
Date:
OBSERVED
CAUSE
IMPLEMENTATION REF
OPPORTUNITY SELECTOR
No
Opportunity
Event:
Team:
Location:
Date:
Ref
No
Opportunity
EASY
HIGH A
LOW B
HARD
C
D
Ref
ACTION CHART
Event:
Page
Location:
N o. Conce rn
Team:
D a te Counte rme a sure
R a ise d
of
Date:
R e sp. T a rge t
D a te
% Comple te
25% 50% 75%
Comple te Confirm OK
100%
D a te
D a te
ACTION CHART
Event:
Page
Location:
No. Comment
Team:
Measure
of
Date:
Who
When
Prog.
SPAGHETTI DIAGRAM
Process:
Team:
Location:
Date:
BOX FLOW CHART
Process:
Team:
Location:
Date:
<----------------- DEPARTMENT/SECTION/AREA -------------->
Operation
Delay
Inspection
Storage
Transport
PROCESS FLOW CHART
No. OPERATION/PURPOSE
Process:
Team:
Location:
Date:
FLOW DEPARTMENT AREA
.O:D:I:S:T
NAME
DIST
TIME
M²
M
MIN
AREA
DIST
TIME
QUANTITY HUMAN
No.
DIST
HUMAN COMMENT
TIME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TOTALS
QUANTITY HUM DIST
HUM TIME
Operation
Delay
Inspection
Storage
Transport
VALUE ADDED
No OPERATION
PROCESS TIMES SUB TOTALS
Process:
Team:
Location:
Date:
VALUE
ADDED
NON-VALUE
No. OPERATION
ADDED
PROCESS TIMES SUB TOTALS
PROCESS TIMES TOTALS
VALUE
ADDED
NON-VALUE
ADDED
SUPPLY CHAIN
MANAGEMENT
Team:
Title:
Date:
MY SUPPLIER
MY PROCESS
MIN
QTY
MY CUSTOMER
MIN
QTY
My Takt time
Supplier Takt time
Suppliers product
My material
Customer Takt time
Customers material
My product
Kanban
Kanban
Type:
Type:
Description:
Description:
Area:
HUMAN WORK
CALCULATION
Team:
Date:
For each part
A
B
C
For each lot
D
E
G
H
P/N
(family)
Qty/yr
•machine
time
1
•=
•walking
time
total of...
•other
time
2 Total per part
(h/yr)
•set-up
time
Batch
size
Total
K
n.working days / yr
WORKING TIME
TOTAL PER DAY
*G
Total set-up
(h/yr)
Total
L
hours/yr
K+L
TOTAL PER
YEAR
J
A
H
A * (B+C+D)
1: Operator's required working time when the machine is in operation
2: Includes the machine loading and unloading
hours/yr
OP
Actual
Objective
Ideal
OP
OP
Team:
Process:
STANDARD WORK IN
PROGRESS
Date:
OP
OP
OP
OP
OP
OP
OP
OP
OP
Process:
STANDARD OPERATION
Date:
Location:
QUALITY
CHECK
SAFETY
OPERATION
STD IN PROCESS
STOCK
STATION
TIME
CYCLE
TIME
LEAD
TIME
FLOOR
AREA
ERROR PROOFING
CURRENT POKA YOKE
POSSIBLE ERRORS
Event:
Team:
Location:
Date:
AVOIDED ERRORS
POKA YOKE TO BE SET-UP
JOB DISTRIBUTION PILLAR
CHART
Operation
Operators
No. Shifts
Subject:
Takt Time = working time / day
=
parts requirement / day
Date:
OPERATIONAL SEQUENCE
CHART
Operation:
Process:
Team:
Location:
Date:
Title:
Team:
Location:
Date:
PART/PROCESS MATRIX
Machine
No
Process
Qty
1
2
3
4
5
6
7
8
9
10
Part #
BASE OPERATIONAL
MEASURES
Process:
Team:
Location:
Date:
Delivery Efficiency:
Total Cycle Time =
:
Production Lead Time =
=
Delivery Efficiency =
TAKT Time:
Daily Available Time =
:
Daily Required Quantity =
=
TAKT Time =
P:D Ratio:
Production Lead-Time =
:
Delivery Lead-Time =
=
P:D Ratio =
Stock Quantities:
Raw Material =
Pre-Cell =
In Cell =
Out Cell =
Post-Cell =
Sub-total =
Customer =
Total =