Transcript CI CHARTS

Kaizen
SMED 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:
OPERATIONAL SEQUENCE
CHART
Operation:
Process:
Team:
Location:
Date:
SMED
SET-UP TIMES
Part:
Team:
M/C:
Date:
CURRENT TIME
No Task/Operation
Internal
External
IMPROVEMENT
OPERATION
CURRENT TOTAL
Tool:
PROPOSED TIME
Internal
IMPROVED TOTAL
Internal: Operations that necessitate the stopping of the machine
External: Operations not requiring the stopping of the machine.
Key Terms: ASSEMBLE, DISMANTLE, USE, TRANSPORT (EMPTY), TAKE, TRANSPORT (FULL),
PUT DOWN, FIND, CHOOSE, INSPECT, DEPLACE (REPOSITION), HOLD, WAIT, LOOK FOR.
External
TOTAL PRODUCTIVE
EFFECTIVENESS
Process:
Team:
Location:
Date:
Availability Rate: (Equipment failure, Set-up & adjustment, Tool change, Start-up)
Available Time
- Down Time
= Availability Rate % =
Available M/C Time
Performance Rate:
Standard Time
X
(Minor stops & idling, Speed loss)
x Units made
= Performance Rate % =
Operating Time
Quality Rate:
X
(Scrap & rework)
Parts Count
- Defects
= Quality Rate % =
Parts Count
Alternatives:
Performance Rate = (Op Time - Perf. loss)/OpT
Quality Rate = (Productive time - Defect time)/Prod Time
=
TPE % =
Quality Loss
Scrap/Rework
Perform. Loss
Speed loss
Stops/Idling
Avail. Loss
Start-up loss
Tool Change
Set-up/adjust
Equip Failure
Run Time
End
Start
TPE OBSERVATION
Equip.:
Name:
Part:
Date:
Remarks
Department:
Machine:
Time After
Time Before
Job begins
on the
Job ends
on the
Time After
Time Before
Job begins
on the
Job ends
on the
Time After
Time Before
Job begins
on the
Job ends
on the
Time After
Time Before
Job begins
on the
Job ends
on the
Time After
Time Before
Job begins
on the
Job ends
on the
Improvement
Measurement
Improvement
Dates
Responsible for follow-up
Problem Description and suggested improvement
Process owner
Scrap &
Rework
Idling,
minor
stoppages
and speed
loss
Set-up &
Adjustment
Tool
Change
Breakdowns,
Start-up
Eater
Date:
Effectiveness Improvement Sheet