One slide Kaizen and Cap-Do (PDCA) cycle hybrid

Maximize the Overall Equipment Effectiveness, Process and Plants Through Uncompromising Elimination of Losses and Continuous Improvement of Performance.

Step 1 – Identify The Situation

• Charter Team
• Collect available Data
• Classify Losses

Step 2 – Justify The Situation

• Stratify Losses
• Select the Subject
• Verify Relevance to Site Master Plan

Step 3 – Understand Ideal Process

• Understand Structure & Function
• Identify Principle of Operation
• Identify Main & Secondary Rules

Step 4 – Grasp Actual Situation

• Collect Data
• Go to the Genba and Investigate
• Identify the Problem
• Establish the Benchmark

Step 5 – Establish The Objectives

• Identify the Measurement
• Determine the Target

Step 6 – Make a Work Plan

• Establish the timeline for completing and assign responsibilities for completing the Kaizen

Step 7 – Perform Cause Analysis

• Apply Analytical tool
• Fabricate Prototype, test theories
• Verify Root Causes

Step 8 – Propose Countermeasures

• Draft Improvement Proposals with SHE review
• Compare Alternate Proposals
• Select the best Proposal
• Document Action Plan (Who, What, When)

Step 9 – Implement Countermeasures

• Carry Out Improvement Plan
• Provide Instruction on Improved Equipment
• Perform Test Operation With Formal Acceptance

Step 10 – Verify Results

• Design & Implement Quality Control System
• Evaluate Results for a set period (i.e. 90 days)
• Check whether Targets have been Achieved
• If Not, return To Step 7

Step 11 – Standardize Improvement

• Draw Up Control Standards to Sustain Results
• Formulate Work Standards and Manuals
• Feed Information Back to Maintenance Prevention program

Step 12 – Future Plans

• Identify Need For Further Kaizens
• Define Opportunities for Replication
• Document Kaizen activity