KAIZEN CHECKLIST

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--- 5S WORKPLACE ORGANIZATION ---
[ ] Sort: Number of Items Removed/Discarded
[ ] Sort: Describe items removed and reason for removal.
[ ] Set in Order: Location of Frequently Used Tools/Materials
[ ] Set in Order: Shadow Board Implementation? (Yes, No, Planned - Date: [DATE])
[ ] Shine: Describe cleaning activities performed and frequency.
[ ] Shine: Last Cleaning Date
[ ] Standardize: Visual Management System in Place? (Yes, No, Partial - Needs Improvement)
[ ] Standardize: What Visual Cues are used? (Floor Markings, Labeling, Color Coding, Shadow Boards, Signage)
[ ] Sustain: Document any challenges and corrective actions for maintaining 5S.

--- PROCESS IMPROVEMENT & WASTE REDUCTION (MUDA) ---
[ ] Cycle Time Reduction Target (seconds)
[ ] Which Muda are present in this process? (Defects, Overproduction, Waiting, Non-utilized Talent, Transportation, Inventory, Motion, Extra-Processing)
[ ] Detailed Description of Current Process (including identified Muda)
[ ] Proposed Improvement Action(s)
[ ] Estimated Reduction in Waste (e.g., % decrease in defects)
[ ] Implementation Start Date
[ ] Target Completion Date
[ ] Potential Risks and Mitigation Strategies
[ ] Level of Employee Involvement (Low, Medium, High) (Low, Medium, High)
[ ] Attach Supporting Documentation (e.g., Value Stream Map)

--- EQUIPMENT RELIABILITY & MAINTENANCE ---
[ ] MTBF (Mean Time Between Failures) - Current Value
[ ] MTTR (Mean Time To Repair) - Current Value
[ ] Last Preventative Maintenance Date (Machine X)
[ ] Maintenance Procedure Followed? (Yes, fully, Mostly, Partially, No)
[ ] Describe any unusual noises or behavior observed during operation (Machine Y)
[ ] Vibration Levels (mm/s) - Reading at Sensor A
[ ] Upload Infrared Thermography Image (Equipment Z)
[ ] Lubrication Condition? (Optimal, Slightly Low, Low, Needs Immediate Attention)
[ ] Describe any corrective actions taken regarding maintenance

--- QUALITY CONTROL & DEFECT REDUCTION ---
[ ] Defect Rate (Current)
[ ] Target Defect Rate
[ ] Common Defect Types Observed (Scratches, Dents, Misalignment, Color Variation, Functional Failure, Other (Specify))
[ ] Detailed Description of a Recent Defect Incident
[ ] Root Cause Analysis Method Used (e.g., 5 Whys, Ishikawa) (5 Whys, Ishikawa (Fishbone), Pareto Chart, Other (Specify))
[ ] Summary of Root Cause Findings
[ ] Corrective Actions Implemented to Address Root Cause
[ ] Date Corrective Actions Implemented
[ ] Defect Rate After Corrective Actions (Follow-up)
[ ] Effectiveness of Corrective Action (Highly Effective, Effective, Somewhat Effective, Not Effective)

--- STANDARD WORK & PROCESS CONSISTENCY ---
[ ] Process Name
[ ] Current Standard Work Instructions (Detailed)
[ ] Cycle Time (Current)
[ ] Takt Time (Calculated)
[ ] Proposed Changes to Standard Work
[ ] Change Implementation Method (Pilot Program, Full Rollout, Gradual Implementation)
[ ] Date of Standard Work Implementation
[ ] Cycle Time Post Implementation
[ ] Resources Needed for Implementation (Training, New Tools, Additional Personnel, Software Updates)

--- MATERIAL FLOW & LOGISTICS ---
[ ] Average Material Travel Distance (meters)
[ ] Material Handling Time (minutes)
[ ] Current Material Movement Method (Manual Cart, Automated Guided Vehicle (AGV), Conveyor System, Forklift, Other (Specify))
[ ] Description of Current Material Flow Bottlenecks
[ ] Potential Bottleneck Areas (Check all that apply) (Receiving, Storage, Workstation Transfer, Shipping, Other (Specify))
[ ] Material Handling Equipment Utilization Rate (%) (<50%, 50-75%, >75%)
[ ] Date of Last Material Flow Analysis
[ ] Proposed Material Flow Improvements

--- EMPLOYEE ENGAGEMENT & TRAINING ---
[ ] Number of Kaizen Suggestions Submitted (per employee/team)
[ ] Summary of Recent Kaizen Suggestion Feedback Session
[ ] Training Topics Requested by Employees (related to Kaizen) (5S, Value Stream Mapping, Problem Solving (e.g., 8D), Root Cause Analysis, Standard Work, PDCA Cycle)
[ ] Employee Perception of Management Support for Kaizen (Strongly Agree, Agree, Neutral, Disagree, Strongly Disagree)
[ ] Employee Comments/Feedback on Kaizen Program (Open Text)
[ ] Date of Last Kaizen Training Session
[ ] Percentage of Employees Trained on Kaizen Principles

--- SAFETY & ERGONOMICS ---
[ ] Near Miss Reporting Frequency (per month)
[ ] PPE Compliance Observed? (Gloves, Safety Glasses, Hearing Protection, Steel Toe Boots, Respirator, High-Vis Vest, All PPE Compliant)
[ ] Observations of Unsafe Acts/Conditions
[ ] Ergonomic Risk Assessment Completed (Last Date)
[ ] Ergonomic Improvements Implemented? (Adjustable Workstations, Ergonomic Tools, Rotation Schedules, Training on Proper Lifting Techniques, None)
[ ] Date of Last Safety Training
[ ] Employee Feedback on Safety Concerns (if any)
[ ] Overall Safety Perception? (Very Positive, Positive, Neutral, Negative, Very Negative)

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