12-Step Kaizen Toolkit

The full process described here: 12 Step Kaizen Story

Step #	Step	Explanation	Form Name
1	Identify The Situation	1) Charter Team 2) Collect the available Data 3) Classify The Losses	Step 1 – Team Charter
2	Justify The Situation	1) Stratify The Losses 2) Select the Subject 3) Verify Relevance to Site Master Plan	Graph provided by FI
3	Understand Ideal Process	1) Understand the Structure & Function 2) Identify the Principle of Operation 3) Identify the Main & Secondary Rules	Step 3 – Understand The Ideal Process
4	Grasp Actual Situation	1) Collect Data 2) Go To the Genba and Investigate 3) Identify the Problem 4) Establish the Benchmark	Graph provided by FI
5	Establish The Objective	1) Identify the Measurement 2) Determine the Target	Graph provided by FI
6	Make A Workplan	1) Establish the timeline for completing and assign responsibilities for completing the Kaizen	Step 6 – Make A Workplan Form
7	Perform Cause Analysis	1) Apply Analytical tool 2) Fabricate Prototype, test theories 3) Verify Root Causes	Step 7 – Basic Analysis 5W1H
7	Perform Cause Analysis		Basic Analysis 5 WHY
8	Propose Countermeasures	1) Draft Improvement Proposals with SHE review 2) Compare Alternate Proposals 3) Select the best Proposal 4) Document Action Plan (Who, What, When)	Step 8&9 Propose and Implement Countermeasures
9	Implement Countermeasures	1) Carry Out Improvement Plan 2) Provide Instruction on Improved Equipment 3) Perform Test Operation With Formal Acceptance	Step 8&9 Propose and Implement Countermeasures
10	Verify Results	1) Design & Implement Quality Control System 2) Evaluate Results for a set period (i.e. 90 days) 3) Check Whether Targets have been Achieved 4) If Not, return To Step 7	Graph provided by FI
11	Standardize Improvement	1) Draw Up Control Standards to Sustain Results 2) Formulate Work Standards and Manuals 3) Feed Information Back to Maintenance Prevention program	Step 11 – M-P Sheet
12	Future Plans	1) Identify Need For Further Kaizens 2) Define Opportunities for Replication 3) Document Kaizen activity	Step 12 – Future Plans
12	Future Plans		Step 12 – Kaizen Summary