Plant Name & Location

Product information

Customer information

No of Kaizens generated in the plant (Month wise break up)

Month Apr09 May09 Jun08 Jul09 Aug09 Sep09 Oct09 Nov09 Dec09 Jan10 Feb10 Mar 10

No of Kaizens Total Employees Kaizens/ Employee/m onth

Kaizen Target: One kaizen/Employee/Month

Then start with Kaizen Theme

Continue

Problem statement / Present status

Why Why analysis

Root cause & Kaizen idea

Countermeasure

Kaizen Results & Benefits

Kaizen sustenance

Horizontal Deployment

Kaizen Idea Sheet

COMPANY LOGO / NAME

TPM Circle No.: TPM Circle Name: Dept:

Activity Loss no./ Step

Result Area

KK

JH

QM

PM SHE OT

DM

E&T

Q - Def. A / B / C

Kaizen No.:
Operation :

Cell No.:

Cell Name:

Machine :

Process / Stage :
(Always opposite to root cause)

Kaizen Theme:
Always start with To prevent /To Reduce / To Increase ( Prevent for failure / rejection / accident etc. To Reduce for time parameters like set up & cost, To increase for productivity)

Idea:

(E.g. Poka Yoke, More friction, Fully, More bolts, More coolant, Big, Short, Can detect, Easy)

COUNTERMEASURE :

Problem / Present status:

(Always starting with "Providing / Changing) (Correct observation. Use of 5W 1H) (When = Trend / Time / Period: Contienous / Discontineous / Rare, Start up / Seasons / Set up), (Who =Men:Day shift / Night shift / New employee / Temporary help), (What =Materials: Lots / Type), (Where = Locations: Part / Range / Process / Equipment), (Which = Trend: Direction e.g. possitive, Negative, Rear, Left, Right etc / Increase / Reduction), (How -How much/How many) = Status: Equipment / Jig / Tools / Accuracy / Please insert graph indicating appearance Machining conditions etc) of the defect on which action is taken. Monitoring for few months is necessary to Why Why analysis in brief: Analysis check effectiveness. showing as how the REAL root cause (Rejection for the specific problem) was identified.

Bench Mark Target KAIZEN Start KAIZEN Finish Team Members:

Benefits:
E.g. Increase production, Reduce time / cost etc

KAIZEN SUSTAINANCE : Why Why Analysis : Results:

(E.g. Reduce time, Reduce frequency, Eliminate, Increase life etc.) What to do :

(Indicating "What to check / audit to ensure that the kaizen will be effective in long run"

How to do :

(Indicating "Howt to check / audit to ensure that the kaizen will be effective in long run"
Root Cause : (E.g. Poka, Less friction, Partly, Less bolts, No coolant, Small, Long, Can not detect, Difficult)

Scope & Plan for Horizontal Deployment

(Implementating this kaizen at all possible cases in existing product.

(Check & confirm repurcations of changes being suggested before implementating) Target Sr Responsibility Model Status no Date Registration no. & Date : Registered by : Manager's Sign :
(Implementating this kaizen at all the possible case in the existing / similar products to arrest possibilities of this defect in similar current products.