Plant Name & Location

Product information

Customer information

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

Month Apr-09

May-09

Jun-08

Jul-09

Aug-09

Sep-09

Oct-09

Nov-09

Dec-09

Jan-10

Feb-10

Mar -10

No of Kaizens

Total Employees

Kaizens/ Employee/month

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

TPM Circle No.: Activity KK JH QM PM SHE OT DM E&T

COMPANY LOGO / NAME TPM Circle Name: Loss no./Step

Result Area P C D S M

Cell No.: Cell Name: Operation :

Kaizen Theme: Idea:

Bench Mark Problem / Present status: Target

KAIZEN StartKAIZEN FinishTeam Members:

Benefits:

Why Why Analysis : Results: What to do :

TargetDate

Registration no. & Date : Registered by :Manager's Sign :

Model

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

(Check & confirm repurcations of changes being suggested before implementating)

Responsibility StatusSr no

(Indicating "Howt to check / audit to ensure that

Scope & Plan for Horizontal Deployment

Dept: Kaizen No.:

COUNTERMEASURE :

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

Machine :

(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 / Machining conditions etc)

(Always starting with "Providing / Changing)

Q - Def. A / B / C

Process / Stage :

How to do :

KAIZEN SUSTAINANCE :

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

(Always opposite to root cause)

(E.g. Reduce time, Reduce frequency, Eliminate, Increase life etc.)

(E.g. Poka, Less friction, Partly, Less bolts, No coolant, Small, Long, Can not detect, Difficult)

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)

the kaizen will be effective in long run"

the kaizen will be effective in long run"

Root Cause :

(Indicating "What to check / audit to ensure that

Please insert graph indicating appearance of the defect on which action is taken. Monitoring for few months is necessary to check effectiveness.(Rejection for the specific problem)

Why Why analysis in brief: Analysis showing as how the REAL root cause was identified.

(Implementating this kaizen at all the possible case in the existing / similar products to arrest possibilities of this defect in similar current products.

Kaizen Idea Sheet