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					                                                     Process Control Map

                                                  Phase #:                                                   Date:
            (Supplier Info. Here)                                               Control in Process Step
                                                             At Supplier                                      In Plant

Part (Name/Number)           Characteristic     During           After      Before       Receiving    Line: Before   Line: In-
                                              Production      Production   Shipping     Inspection     Operation     Process     End of Line




                                                                                                                                               Error Proofing

                                                                                                                                               Mistake Proofing




                                                                                                                                               100% Visual Check



                                                                                                                                               Random Visual Check
Control Type

Error Proofing

Mistake Proofing
100% Inspection by
Measuring
Statistical Process
Control
100% Visual Check
Random Inspection by
Measuring
Random Visual Check
                                                                               5 Conditions for Zero Defects

    Part/Characteristic

    Supplier
                                                                      ANSWER                                                                    SCORE

#              QUESTION                       1                           3                           5                 PHASE 0   PHASE 1   PHASE 2     PHASE 3   PHASE 4   PHASE 5
                                                             There are defined
    Is the quality               There is a list of                                      There are defined
                                                             numerical parameters
1   characteristic clear?        characteristics (no                                     tolerances for the
                                                             (measuring unit for each
    (Process, not product)       parameters)                                             characteristic
                                                             characteristic)
                                 Low Cpk (<1.0). Many
    What is the supplier's                                   1<Cpk<1.33. Some, or        Certified supplier with
2                                problems are due to the
    capability?                                              sporadic, problems          Cpk>1.33
                                 supplier
    Is there a clearly defined                               There are defined           There is a good, effective
                                 No standards, random
3   inspection method for                                    procedures, and good        and efficient level of
                                 inspection
    incoming material?                                       application of them         inspection
    Is it possible to avoid
                                                             Possible, with high
4   defective materials being Not possible                                               Yes, Poke Yoke used
                                                             inspection costs
    used?
                                                             Yes, some scrap and
    Is it easy to recover        Very difficult, scrap and   few/no problems in final    It is easy to resolve issues
5   process issues due to        quality issues in final     assembly. (I can often      because scrap if found at
    defective materials?         assembly                    localize the scrap at the   receiving inspection
                                                             workstation)
                                                                                                   TOTAL                 0%        0%        0%          0%        0%        0%
                                                                                                               DATE
     4M: Cause - Effect
MATERIAL




METHOD
Effect
         MACHINE




         MAN
                                             $1,000          $10,000      $20,000    $100,000


                                                          1 week
                                                                       <1 month
                                                                                    1<3month

                                                                                                     > 3 months



                Quick                      Standard                     Major                Advanced
When to use

          Always start with QK
       Use when problem is mostly     If you have tried some
          defined and data are      activities and not achieved                      Only diff from major kaizen is
            available readily                  results                                     the tools you use
                                    Apply when the problem is                         Normally used when Major
                                    complex and solutions are                        kaizen conducted, yet issue
                                         not quickly evident                                     remains

                                                                                        Also use when the only
                                                                                       acceptable target is zero




Who is involved

               Operator                      Operator                  Operator                 Operator
                                              Maintenance                   Maintenance                   Maintenance


                                               Supervisor                    Supervisor                    Supervisor


                                                                              Mfg Eng                       Mfg Eng


                                                                               Ind Eng                       Ind Eng


                                                                                                       6Sigma Black Belt


                                                                                                         Outside Expert


Key tools

            Operator Suggestions              All QK Tools                  All SK Tools                  All MK tools


                   Tags                    WO Methodology                      PFMEA                          PPA

                                                                      Quality 7 Step Problem
                    3G                      AM Methodology                    Solving                         DOE


                  5W&1H                 Professional Maintenance    7 Steps of Machine Quality             Six Sigma


                    4M                                                                                      X Matrix


                   5Why                                                                                    QM Matrix


                  SMART                                                                                Hypthesis testing


            Waste Identification




FORMAT

                 8 1/2 X 11                     11 x 17                    E size print out        Multiple 8 1/2 x 11 sheets

                                                                    Data managed by hand on       Data managed by hand on
              Written by hand               Written by hand                shop floor                    shop floor
          Typed when noted for
       potential expansion or further                              Computer based format         Computer based format
                  training                       Typed             (pictures inserted in file)   (pictures inserted in file)
Posted in area - visual on    Posted in area on pole next    Must have standard project Must have standard project
      spiral holder                     to aisle                        board
                                                             Wehen comlpete - Reprint                board
                                                                                          Wehen comlpete - Reprint
                                                            final version on 11x17 sheet final version on 11x17 sheet
                                                               and post on pole next to     and post on pole next to
                                                                         aisle                        aisle
                                                                                           Board remains in area for
                                                                                            minimum of 3 months to
                                                                                                 monitor results

Maintain publications for 1   Maintain publications for 6   Maintain publications for 6   Maintain publications for 6
          year                         months                        months                        months
nths
Note chart of results
                        Note that a Quick Kaizen is done by
                        hand!! Sketches by pen. This should be
                        done on the shopflloor by operator,
                        leading hand and/or teamleader




Note chart of results
                                                                                                                                                                                                      Dept/MBU
                                                                        QUICK KAIZEN
Plant:                                                                                                                                                                                                Machine/Area/Station:
                                                                    PDCA (Plan-Do-Check-Act)
                                                                                                                                                                                                      Project Number:

Theme:                           Add Description of Project                                                                                                                                                                            Cost Center

                                 S (Safety)                         WO (Workplace Organization)                         AM(Autonomous Maintenance)                                PM(Professional Maintenance)
  Category                       QC (Quality Control)               L&CS(Logistics & Customer Service)                  PD(People Development)                                    E(Environment)
                                 EEM (Early Equipment Management)                                                       EPM (Early Product Management)                            FI(Focused Improvement)
                                                                                                          Machine
                                 Description of the phenomenon with (eg. 5W&1H )                                                          Description of the solution (use sketches if possible)
 PLAN                                                                                           Man

                                                                                                                     Pain
                                                                                            Method
                                                                                                          Material
                                                                                                                                                                                                                                   DO
Make a clear phenomenon description:
The more clear and specific, the better and the easier the solution will be to find (3G, 5W1H, Spaghetti Diagram)
Why are you working on this project? Clearly describe the pain incurred because of the problem.
(e.g. John in Station 2 currently walks 10 steps per AFX combine to get air cleaners for a loss of $153/year.)                            Choose the selected solution (use sketch)
Which losses are caused?                                                                                                                  Who is the responsible for implementation?
E.g. Safety, micro stoppages, breakdowns, speed losses, NVAA                                                                              When will it be realized/complete?
What is the loss associate with this problem?                                                                                             What will it cost?
Express in hours, dollars, safety risk, production numbers                                                                                "COST" in this form is "what outlay of money or time is required to fix this specific problem"
Define the Root Cause (use 4M & 5why)

Evaluate different solutions: think about 3-5                                                   Must Provide Sketch
solutions, evaluate critical factors, look at cost and
easiness for implementation, use sketches

Formulate a target (SMART)
Specific
Measurable
Achievable
Realistic
Time Based
                        Standardization and Expansion Plan                                                                                                                  Verify Results
         ACT                                                                                               CHECK                          Did the chosen solution bring any improvement?
                                                                                                                                          How do you know? Monitor for some time.
                                                                                                                                          Has the target been achieved? YES/NO
                                                                                                                                          Has an unforeseen problem occurred? If yes which actions have been taken to solve it
                                                                                                                                          Where possible, chart the results over time
Has the target been achieved? If not what actions?                                                         Standard metrics
                                                                                                           (Time, Distance, Steps, Pieces, People, Activities, Space)
Are any further actions necessary to sustain the new standard over all the shifts?                                                                                      Before      After
                                                                                                           # units/ day required by customer
Can this Quick Kaizen be applied in other places? YES/NO                                                   # people/ unit                                                                             Calculation Standards
                                                                                                           # steps / unit
                                                                                                           Distance traveled / unit
What did you put in place to ensure this problem never repeats?                                            Time / unit
                                                                                                                                                                                                     Walking Standards
OPL, SOP, Training Course, Poka Yoke, SPC, etc.                                                            # Defects / month
                                                                                                           # Breakdowns / month                                                                                  2.5 Walking Speed (Miles/Hr)
What new standards need to be documented and published?                                                    Rework time/ defect
SOP, JES                                                                                                   Repair or wait time / breakdown                                                                  5280 Ft per Mile
                                                                                                           Cycle time
                                                                                                                                                                                                                  2.5 Feet per avg step
                                                                                                           Qty pieces (stock/inventory)
List additional Improvements                                                                               Unsafe conditions/ acts                                                                               240 Work Days per year
Space savings, Team Moral, Better working environment, improved ergonomics                                 Area required (ft^2)
                                                                                                                                                                                                      $ 0.0057 Cost per step
# People involved, increased training
                                                                                                           Cost of project                                                                            $ 0.0023 Cost per foot traveled
                                                                                                           Time of team members required for project (hrs)


               4M              5W1H                      AM Tag                     FMEA                  NVAA                            Poka Yoke                     QM Matrix                     SMED                      X Matrix
Tools used:
               5S              5why                      ABC Class.                 Kanban                OPL                             QA matrix                     Six Sigma                     VSM                       Others
Project leaderStarting Date:    # People Involved        Implementation team:          Completion Date:              Cost ($):                    Benefits ($)                   Other Results:              Benefit/Cost           Verifier & Date::

                                                                                                                                                                                                                     0




                                                                                                                                                                Last Updated 2008 November 5
                     QUICK_KAIZEN-Instructions                                                                                                 D:\Docstoc\Working\pdf\433ab043-277c-46cd-9d05-6bad4f4213f7.xlsx                                         Owner: WCM Manager
                                                                                                   QUICK KAIZEN                                                                                   Dept/MBU

Plant:                                                                                                                                                                                            Machine/Area/Station:
                                                                                               PDCA (Plan-Do-Check-Act)                                                                           Project Number:
Theme:                                                                                                                                                                                                                           Cost Center

                                               S (Safety)                         WO (Workplace Organization)                     AM(Autonomous Maintenance)                  PM(Professional Maintenance)
          Category                             QC (Quality Control)               L&CS(Logistics & Customer Service)              PD(People Development)
                                               EEM (Early Equipment Management)                                                   EPM (Early Product Management)
                                                                                                                                                                              E(Environment)                                                                  Man                Machine
                                                                                                                                                                              FI(Focused Improvement)
                                                                                                                                                                                                                                                                    Fill In
                                                                                                                                                                                                                                                  Fill In
         PLAN                                Description of the phenomenon with (eg. 5W&1H )                                                    Description of the solution (use sketches if possible)                                 DO



                                                                                                                                                                                                                                                                                            Fill In Problem
                                                                                                                                                                                                                                                    Fill In
                                                                                                                                                                                                                                                                       Fill In



                                                                                                  Must Provide Sketch

                                                                                                                                                                                                                                                              Method             Material




                                             Standardization and Expansion Plan                                                                                         Verify Results
            ACT                                                                                                          CHECK




                       4M                    5W1H                     AM Tag                      FMEA                  NVAA                    Poka Yoke               QM Matrix                 SMED                    X Matrix
         Tools used:
                       5S                    5why                     ABC Class.                  Kanban                OPL                     QA matrix               Six Sigma                 VSM                     Others
Project leader              Starting Date:     # People Involved      Implementation team:           Completion Date:          Cost ($):               Benefits ($)         Other Results:               Benefit/Cost         Verifier & Date::

                                                                                                                                                                                                             0.00




                                                                                                                                                                              Last Updated 2008 November 5
                       QUICK_KAIZEN-White                                                                                                                    D:\Docstoc\Working\pdf\433ab043-277c-46cd-9d05-6bad4f4213f7.xlsx                                                      Owner: WCM Manager
                                                                                                                                                                                      MBU:
                                                                                     STANDARD KAIZEN
Plant:
                                                                                   PDCA (Plan-Do-Check-Act)                                                                           Machine/Area/Station:
                                                                                                                                                                                      Project Number:
Theme                                        Add Description Of Project                                                                                                                                                                                                                                        Cost Center

                                              S (Safety)                         WO (Workplace Organization)                           AM(Autonomous Maintenance)                              PM(Professional Maintenance)
    Category:                                 QC (Quality Control)               L&CS(Logistics & Customer Service)                    PD(People Development)                                  E(Environment)
                                              EEM (Early Equipment Management)                                                         EPM (Early Product Management)                          FI(Focused Improvement)


                                                                                                                 Root Cause Definition / Loss Evaluation
    PLAN                                                                                                                                                                                                                                                                                             DO
                                                                                                                                                                                                                                                                                                 10h 3 DM

                                                                                                   4. Determine the principal causes
                                                                                                   (Recommended tools: 4M & 5Why or 7Step or FMEA )

             Description of the phenomenon                                                                                                                                                                                                            7. Description of the solution
                                                                                                                 Man          Machine
  1. Description of the phenomenon (provide picture/sketch)

  2.Type of Loss/Waste (Safety Risk, Yield Loss, Material loss, NVAA, etc...)
                                                                                                                                                             Problem
  (Muda: Wait, Move, Stock, Transport, Process, Defect, Overproduction)                                                                                                                                                           (provide hand sketches, drawings, or pictures)
  3. What are the costs related to the waste/loss                                                                                         (easiest to draw form by hand)
                                                                                                     Method            Material
  Recommended Tools to use: 5G or 5W&1H
                                                                                                   5. Possible Countermeasures

                                                                                                            Target                                                                                                                           8. List team members & their job responsibilities

                                                                                                   6. Define SMART target                                                                                                                          9. Action Plan with dates & owners
                                                                                                                                          Specific
                                                                                                   (level of improvement to reach)        Measurable
                                                                                                                                          Achievable
                                                                                                                                          Realistic                                                                                                Gantt Chart or Time Line
                                                                            1) Understand the problem
                                                                                                                                          Time based                                                                                         Who is responsible for implementation
                                                                            2) Sketch the phenomena                                                                                                                                                     Cost of activity
     Must Provide Sketch/Picture of Phenomena                               3) Identify the causes
                                                                            4) Verify the causes
                                                                            5) Identify the solutions and
                                                                            establish priorities.                                                                                           6) Apply solutions on
                                                                                                                                                                                            experimental basis.


                                                 8)Standardize, Document,
                                                 Communicate & Train & Expand                            ACT                                            Standard metrics
                                                                                                                                                        (Time, Distance, Steps, Pieces, People, Activities, Space)
                                                                                                                                                                                                                                                                                                                  CHECK
                                                                                                                                                                                                                         Before      After     Check which level of improvement has been obtained
                                                                                                                                                        # units/ day required by customer
                                                                                                                                                        # people/ unit
                                                                                                                              7) Verify the             # steps / unit
                                                                                                                                                                                                                                               Provide visual of results (SPC, Charting, Spaghetti Diagram)
Are any extra actions necessary to obtain the target/objectives?                                                              solutions                 Distance traveled / unit                                                               Has the scope been obtained? YES / NO
                                                                                                                              against                   Time / unit

Which actions are necessary to guarantee the sustaining of the new standard?                                                  expected                  # Defects / month
                                                                                                                                                                                                                                               Were there unforeseen situations YES/NO (describe which ones)
                                                                                                                              results.                  # Breakdowns / month
                                                                                                                                                        Rework time/ defect
Which type of control actions have to be introduced? (Poka Yoke, SOP, or OPL?)                                                                          Repair or wait time / breakdown
                                                                                                                                                        Cycle time
                                                                                                                                                        Qty pieces (stock/inventory)
Evaluate cost/benefit analysis (REQUIRED)
                                                                                                                                                        Unsafe conditions/ acts
                                                                                                                                                        Area required (ft^2)
Is there possibility to introduce this Kaizen/Improvement in another area?: YES/NO
                                                                                                                                                        Cost of project
List additional Improvements                                                                                                                            Time of team members required for project (hrs)
Space savings, Team Moral, Better working environment, improved ergonomics, etc
                    4M                  5W1H                    AM Tag                             FMEA                     NVAA                       Poka Yoke                      QM Matrix                                                SMED                                         X Matrix
    Tools used:
                    5S                  5why                    ABC Class.                         Kanban                   OPL                        QA matrix                      Six Sigma                                                VSM                                          Others
Project leader         Starting Date:         # People Involved        Implementation team:            Completion Date:              Cost ($):                Benefits ($)                                Other Results:                                       Benefit/Cost                                 Verifier & Date::

                                                                                                                                                                                             (e.g. safety improvement, avoid $ increase)                            0                                  Savings validation from CD




         STD_KAIZEN-Instructions                                                                                                              Last Updated 2008 November 5                                                                                                                                                      WCM Leader
                                                                                                                            D:\Docstoc\Working\pdf\433ab043-277c-46cd-9d05-6bad4f4213f7.xlsx
                                                                                                                                                                                                                                                                                                          MBU:
                                                                                                                                                                 STANDARD KAIZEN
                                                                                                                                                                                                                                                                                                          Machine/Area/Station:
Plant:
                                                                                                                                                               PDCA (Plan-Do-Check-Act)                                                                                                                   Project Number:
                                                                                                                                                                                                                                                                                                                                                                                Man                Machine
Theme                                                                                                                                                                                                                                                                                                                                              Cost Center                        Fill In
                                                                                                                                                                                                                                                                                                                                                                    Fill In
                                                                    S (Safety)                                 WO (Workplace Organization)                                               AM(Autonomous Maintenance)                                                    PM(Professional Maintenance)
                                                                    QC (Quality Control)                       L&CS(Logistics & Customer Service)                                        PD(People Development)                                                        E(Environment)
             Category:
                                                                    EEM (Early Equipment Management)                                                                                     EPM (Early Product Management)                                                FI(Focused Improvement)


                                           Description of the phenomenon                                                                            Root Cause Definition / Loss Evaluation
                 PLAN                                                                                                                                                                                                                                                                                                                           DO
                                                                                                                                                                                                                                                                7. Description of the solution                                                                                                               Fill In Problem
                                                                                                                                                                                                                                                                                                                                                                      Fill In
                                                                                                                                                                                                                                                                                                                                                                                         Fill In




                                                                                                                                                                                                                                                                                                                                                                                Method             Material


                                                                                                                                                                                                                                                                8. List team members & responsibilities

Must Provide Sketch/Picture of Phenomena




                                                                                                                                                                                                                                                                9. Action Plan with dates & owners


                                                                                                                                                    SMART Target




                                                                                                                                             ACT                                                                                                                                                                                           CHECK




                                    4M                            5W1H                                 AM Tag                                       FMEA                         NVAA                                     Poka Yoke                             QM Matrix                                 SMED                       X Matrix
             Tools used:
                                    5S                            5why                                 ABC Class.                                   Kanban                       OPL                                      QA matrix                             Six Sigma                                 VSM                        Others
Project leader                                 Starting Date:               # People Involved                 Implementation team:                           Completion Date:                 Cost ($):                               Benefits ($)                            Other Results:                          Benefit/Cost              Verifier & Date::

                                                                                                                                                                                  $                        1,370.00        $                         5,332.90                                                            3.89




           STD_KAIZEN-White                                                                                                                                                                                                        Last Updated 2008 November 5                                                                                                                                                  WCM Leader
                                                                                                                                                                                                                 D:\Docstoc\Working\pdf\433ab043-277c-46cd-9d05-6bad4f4213f7.xlsx
5W1H Analysis Sheet
4M

				
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