101 Kaizen Templates

21 Articles

Brilliant Value Stream Mapping Icon Fonts

By Jon Miller - October 20th, 2009

Jamie Flinchbaugh shared on his blog yesterday a brilliant find. The nice folks at Ambor have developed several very useful fonts for lean. Skill Matrix Font The Harvey Balls ideograms are great for filling out the skill matrix. Compar

101 Kaizen Templates: Workplace 5S Audit Sheet

By Jon Miller - March 19th, 2008

Why would the world need another Workplace 5S Audit Sheet? Well, kaizen never ends, that’s why. Although it does rest sometimes. On this 5S audit sheet there are 10 questions, two in each of the five categories of 5S. You need t

101 Kaizen Templates: PWINT Kaizen Worksheet

By Jon Miller - March 18th, 2008

The idea of PWINT kaizen is to look for kaizen ideas that are within a narrowly defined process band, with a particular perspective of observation. The letters PWINT stand for Processing, Waiting, Inspection and Transportation. It̵

101 Kaizen Templates: Production Control Board

By Jon Miller - March 13th, 2008

The hourly production control board, otherwise known as the hour by hour chart, is used to monitor the progress or output of a process against plan. The advantage of this kaizen template is in its simplicity, near real time performance

101 Kaizen Templates: Kaizen Newspaper

By Jon Miller - March 7th, 2008

One of the guidelines to operating an effective suggestion system is to limit the scope of suggestions. A person’s kaizen ideas should focus on the work they themselves do. Sometimes teams of people develop kaizen ideas but the same

101 Kaizen Templates: Kaizen Idea Suggestion Form

By Jon Miller - March 3rd, 2008

Long-term success in becoming a Lean or Agile organization depends on making many small changes. The kaizen philosophy and its many thinking tools helps with this. The suggestion system, when combined with coaching of ideas, is also a

101 Kaizen Templates: Lean Leadership Self Check

By Jon Miller - February 26th, 2008

In a blog post, Ron Pereira explains that a Real Leader, “…listens, respects, challenges, disciplines, and genuinely cares about his or her employees. Yes, real leadership is hard to practice. But just like a healthy and ha

101 Kaizen Templates: Daily Hansei Sheet (Pluses & Deltas)

By Jon Miller - February 20th, 2008

Ron Pereira wrote an article titled “How not to screw up pluses and deltas”. It gives useful tips on how to properly review at the end of a day of class room training or a shop floor kaizen. The pluses and deltas activity i

101 Kaizen Templates: Motion Economy Chart

By Jon Miller - February 16th, 2008

One of the toughest things that a kaizen consultant has to do is to tear down the results of past kaizens. This is hard because people develop a sense of ownership of the status quo they helped to build. Even if the status is not good,

101 Kaizen Templates: Spaghetti Diagram

By Jon Miller - February 12th, 2008

The spaghetti diagram needs very little introduction. It’s so named because the lines movement drawn on this diagram resemble a pile of tangled noodles. It’s a movement path diagram by a more appetizing name. Seeing Wasted

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