Declaration on IP (Intellectual Property) Right:

This Excel file as well as relatedhave presentation been developed ba

I tried to keep the original sources but often it was not possible due to

Under FAIR use policy of IP we ONLY can use this presentation for our

Purpose of this presentation to provide awareness and encourage jum

n been developed based on Six Sigma and other quality materials collected from differen

as not possible due to lack of info of creator.

presentation for our individual or group learning purpose but not for commercial usage

s and encourage jump start on process improvement event.

ollected from different sources online.

or commercial usages!

Kaizen Event Charter

Process to be Targeted

Objective/Target of Event

Brief Process Description

Boundaries of the Defined Process

Resources for Event (if any)

izen Event Charter

Starting Date
End Date
Team Leader
Team Members

Facilitator
Coach

Process Excludes

MEETING SUMMARY
MEETING INFORMATION
DATE

4/2/2003

PREPARED

Pat

FACILITATOR

Jerry Barron

PLACE

Sirrine Cinference Room

SUMMARY

DECISIONS and
AGREEMENTS

TEAM MEMBERS
Karen
Tom
Helen
Pat
Bob

To present our findings and proposed future states to Dr. Scott and d
eport and prsesentation.

After getting some feedback from Dr. Jerrold, the group has decided to
the design of the system using the budget fomrs that Helen presented
discussed and adjusted to meet the nees of the facility manager

ACTIONS TO BE TAKEN
1. Document meeting with area contacts and submit those to Helen
2. Area teams should be sure to meet before next meeting and establish risk considerations for
executive summary.
3. Submit any information that you would like included in the PowerPoint presentation to Tom
before next meeting.
4. The next meeting will be held in the library conference room 101 on April 9th.

ARY

TEAM MEMBERS ATTENDING

Karen
Tom
Helen
Pat
Bob

x
x
x
x

tes to Dr. Scott and determine next steps for

esentation.

group has decided to base our futrue state on

that Helen presented. It will be further
acility manager

BY WHOM?

WHEN?

All

9-Apr

Area team scribes

Continuous

Area teams

9-Apr

Area teams

9-Apr

Five Day Focused Improvement Event - AGENDA

Sunday
Planning Day

8:30 am

Kick-Off Event Meeting

9:00 am
9:30 am

w/ Site Leader
Team Picture
Charter Review - Why are
we here?
Kaizen Overview
Brainstroming

10:00 am
10:30 am
11:00 am
11:30 am
12:00 noon
12:30 pm
1:00 pm
1:30 pm
2:00 pm
2:30 pm
3:00 pm
3:30 pm
4:00 pm
4:30 pm
5:00 pm

Monday
Doing Day
Core Team Sharing

Additional Training as
needed

Prioritize Issues
Brainstorm

Affinity Diagram

Potential Solutions

Lunch

Lunch

Perato
Discovery
VSM As-is
Current State
VSM New
MoM
Weekly Plan

Leader Event Report-Out

Tuesday
Doing Day
Core Team Sharing

Wednessday
Checking Day
Core Team Sharing

Change Day
Implementing
Try Storming

Validation
Verifying new
Methods
Refining

Lunch

Lunch

Continue Change

Validation

Leader Event Report-Out

Leader Event Report-Out

Be prepared to stay
late tonight!

Be prepared to stay
late tonight!

Thursday
Acting Day
Core Team Sharing

Preparing Report Out

Final Report Out
+ attendance at report out

Lunch

Follow these instructions to complete a Value Stream Map (VSM)

To construct a new VSM:

Step 1:

Goto the 'VSM Symbols' tab

Step 2:

Click on the object required for the VSM

Step 3:

Copy the object

Step 4:

Goto the 'VSM Template' tab and paste the object

Step 5:

Repeat steps 1 - 4 for all required objects

Step 6:

Goto the 'VSM Template' tab and complete the data boxes

Step 7:

Complete the Lead Time ladder

To delete an existing VSM:

Step 1:

Goto the 'VSM Template' tab

Step 2:

Select one of the objects

Step 3:

Select CTRL + A

Step 4:

Select the Delete key

Purchasing
Supplier

Cycle Time

100

Change Over Time

100

Up Time (%)

100

Yield (%)

100

# Shifts

100

# Operators

100

Stamp
Qty: 6000

Cycle Time

100

Change Over Time

100

Up Time (%)

100

Yield (%)

100

# Shifts

100

# Operators

100

1200
100

MRP

Trim
Qty: 2500
Cycle Time

100

Cycle Time

Change Over Time

100

Change Over Time

Up Time (%)

100

Up Time (%)

Yield (%)

100

Yield (%)

# Shifts

100

# Shifts

100

# Operators

# Operators

28000
100

Grind

Polish
Qty: 3200

Cycle Time

100

Cycle Time

100

Change Over Time

100

Change Over Time

100

Up Time (%)

100

Up Time (%)

100

Yield (%)

100

Yield (%)

100

# Shifts

100

# Shifts

100

100

# Operators

100

# Operators

1400
100

100

Customer

Takt Time

100

Demand (Units)

100

Frequency

100

100
100
100
100
100
100

15000

Lead Time
Cycle Time

46000
400

Purchasing
Supplier

Cycle Time

100

Change Over Time

100

Up Time (%)

100

Yield (%)

100

# Shifts

100

# Operators

100

Stamp
Qty: 6000

Cycle Time

100

Cycle Time

Change Over Time

100

Change Over Time

Up Time (%)

100

Up Time (%)

Yield (%)

100

Yield (%)

# Shifts

100

# Operators

100

# Operators

1200
100

MRP

Trim

Grind
Qty: 2500

Qty: 3200

Cycle Time

100

Cycle Time

100

Change Over Time

100

Change Over Time

100

Up Time (%)

100

Up Time (%)

100

Yield (%)

100

Yield (%)

100

# Shifts

100

# Shifts

100

100

# Operators

100

# Operators

28000
100

100

Customer

Takt Time
Demand (Units)
Frequency

Polish
Qty: 3200
Cycle Time

100

Change Over Time

100

Up Time (%)

100

Yield (%)

100

# Shifts

100

# Operators

100

1400

15000
100

100
100
100

Lead Time
Cycle Time

46000
400

Production Pull

Production Push

Manual Information Flow

Electronic Information Flow

Cycle Time
Change Over Time
Up Time (%)
Yield (%)

100
100
100

# Shifts

100
100

# Operators

100

Data Table

Go See

Emergency Stock

Inventory Withdraw

Operator

Parts Storgae

Produce Part - Kanban Card

Transfer Part - Kanban Card

Opportunity for Improvement

Qty:

Customer

Process Step A

Opportunity for Improvement

Kanban Card Box

Inventory

Customer or Supplier

Timeline Elements

Process Step

Load Leveling Box

Batch Kanban Card

First In - First out

Transportation

Frequency

Frequency

Frequency

Frequency

Frequency

LEAD
TIME (s)
VALUE
TIME (s)

0
0

Pareto Analysis
[Herff Jones ]
[Brief Project Description]
[Date]

[Chart Title]
60

100%

50

80%

40
60%

Defects

Cumulative %

30
40%
20
20%

10
[42]

0%

Causes
Vital Few

Useful Many

Labels

Cumulative%

[42]

Cut Off %

The first 3 Causes cover 87.96% of the Total Defects

Cumulative Percentage Cutoff:

# Causes
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

2009 Vertex42 LLC

Glue
Binding
Button
Pressure Applied
Cause # 5
Cause # 6
Cause # 7
Cause # 8
Cause # 9

80%

Defects

Cumulative%

50
30
15
5
3
2
1
1
1

46.3%
74.1%
88.0%
92.6%
95.4%
97.2%
98.1%
99.1%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%

Templates by Vertex42.com

As-is
Lead Time
Cycle Time

NEW
46000
400

Differrence
46000
0
400
0

50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
Lead Time

As-is
NEW
Differrence

Cycle Time

As-is
NEW
Differrence

Quality Tools
Cause and Effect Diagram
Description

Measurement

This template illustrates a Cause and Effect

Diagram, also called a Fishbone or Ishikawa
Diagram. A detailed discussion of Cause and
Effect Diagrams can be found at www.ASQ.org

Materials

Lab Error

Raw Materials

Analyst

H2O

Improper Calibration

Learn About C and E Diagrams

Calculation

Instructions

Enter the Problem Statement in box

provided.

Brainstorm the major categories of the

problem. Generic headings are provided.

Solvent Contamination

Supplier

In lab

Write the categories of causes as branches

from the main arrow.

Learn More

Rust Near Sample Point

To learn more about other quality tools, visit the

ASQ Learn About Quality web site.

Exposed Pipe

Learn About Quality

Tools

Environment

Manpower

Materials

Method

Raw Materials

Analytical Procedure

H2O

Not Followed

City

Calibration

Plant System
Lab Solvent
Contamination

Sampling

Supplier

Iron Tools
Problem Statement

In lab

Dirty Bottles

Iron in Product

Inexperienced Analyst

Materials of Construction

Rusty Pipes

Maintenance

At Reactor

Opening Lines

At Sample Point

Iron Tools

Heat Exchanger Leak

E470

E583

Manpower

Machine

Problem Statement

Iron in Product

Supplier

Input

End User

Trouble Ticket (TT)

HRD
HRD

HD Supervirosr
IT Assistants

Vendor

HD Software

Metrics
Response Time
2 Yrs Exp. Of HD Supervisor
ITIL Foundation
99% Availability of HD Software

Process

Output
Resolved TT
Open TT

Log TT

Aanlyse

Troubleshoo
t

Close TT

Metrics
Loging TT < 10 Min
Analysing TT < 2 Min
Assigning Support Engineer TT < 1 Min
P1 Troubleshooting < 2 Hr
P2 Troubleshooting < 8 Hr
P3 Troubleshooting < 16 Hr
P4 Troubleshooting < 5 Business days
P5 Troubleshooting < 30 Business days
Closing TT < 1 Min

Assign
Support
Engineer

Metrics
Resolution or Restoration Time
Workarround / Permanent fix

Customer
End User

Cause
Cause &
& Effect
Effect Matrix
Matrix Linking
Linking
to
to Fishbone
Fishbone and
and SIPOC
SIPOC
Rating importance to Customer (from VOC) --

0 = No Relationship
1 = Minimal Relationship
Relationship

Sl#

Process Step/ Fishbone

1 Man
2 Machine
3 Material
4 Material
5 Method

3 = Moderate Relationship
9 = Significant

Process Input from VSM

Overcooked patty
Under cooked patty
Dirty
Overcooked patty
Not prepared for topping

10
Ooutput1 - Great Taste

Change Management

9
1
3
1
1

Those rows with high scores are the ones that indicate important, high-leverage input factors. You can effe
Each of the row needs to be varified again with Pareto Chart too. Then finalize the inputs that

Ooutput2 - Not over

cooked

Output3 - Topping
capability

9
1
1
3
1

0
1
9
9
1

Total
135
83
89
79
21

put factors. You can effectively ignore the low scores from further consideration.
nalize the inputs that is more important to take care 1st.

Quality Tools
Flow Chart
Description

Instructions

This template allows the user to develop a process flow chart,

also called process flow diagram. A detailed discussion can be
found at www.ASQ.org

Begin the flow chart with a Start/End symbol. A

to the grid for easy alignment.

Connectors link process steps and automatically

symbols.

End with a Start/End symbol. The delete key wil

selected symbol

Re-set the print area for larger charts

Learn About Flow Charts

Receive Order
Start

Text

/ End

Step

Enter Order in
System

Connector

Credit Check

Text

No

Decision

Refuse
Order

OK?
Yes

No
Text

Flowchart

Link

Yes

Check Inventory
Input/

Output

Text

No
Document

OK?

Check Materials
Needed

Yes

Text
OK?

Text

Order Material

Learn More

rt with a Start/End symbol. All symbols snap

y alignment.

ocess steps and automatically snap to

nd symbol. The delete key will remove a

ea for larger charts

Order Material

To learn more about other quality tools, visit the ASQ Learn About
Quality web site.

Learn About Quality

Sl#

Name

Attened in Training (Y/N)