12 Step Kaizen Toolkit

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Full process described here: 12 Step Kaizen Story

Step # Step Explanation Form Name
( Click on the name to go to the form)
1 Identify The Situation 1) Charter Team
2) Collect the availale Data
3) Classify The Losses
Step 1 – Team Charter
2 Justify The Situation 1) Stratify The Losses
2) Select the Subject
3) Verify Relavance to Site Master Plan
Graph provided by FI
3 Understand Ideal Process 1) Understand the Structure & Function
2) Identify the Principlpe 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
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
Step 12 – Kaizen Summary

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