Questionnaires are commonly used in academic research, marketing research, organizational behavior studies, and in quality and process improvement initiatives.
To illustrate how a check sheet functions in practice, consider the example of a defect classification check sheet. This tool is used to track and categorize defects to understand their frequency.
Kanban boards can vary by splitting the “Doing” column into smaller steps, adding buffer columns between stages, and using horizontal lanes to distinguish teams, priorities, or work types.
There are no strict rules for designing a Kanban board. Team can customize their boards with features that suit their processes, such as a “Discarded” area, a “Waiting” area, a column for “Today’s” activities, and so on.
Kaizen activities can be implemented through these following steps. A typical Kaizen event begins with selecting the right problem, one that is significant to the business and can create real impact.
Specific supplies and toolbox are needed in the area where the Kaizen event is taking place. In production areas, supplies may include basic hand tools, tape measures, timers, scissors, marking tape, cleaning materials, safety equipment, carts, and bins.
Many tools and templates are available to support Kaizen events and help turn Kaizen from an idea into real action. These tools ensure that ideas are captured, progress is tracked, and improvements are measured.
After the event, a kaizen report should be prepared to summarize what was accomplished, the improvements made, and how the gains will be sustained. The report may include charts, process maps, before-and-after photos, and key results from the event.
Kanban cards are the physical or digital tools that control the production process in a pull system. Each card represents authorization to make or move items based on actual demand rather than forecasts.
A Production Kanban authorizes the production of a specific quantity of parts when demanded by a downstream process. When a customer process requires more items, the production Kanban signals the supplying process to produce the exact quantity needed to meet the demand.
A Withdrawal Kanban authorizes the movement of parts, materials or supplies from one location to another, typically from storage to production areas. When items are consumed, the withdrawal Kanban triggers replenishment by moving the correct quantity to where it is needed.
The two-card Kanban system uses both Production and Withdrawal Kanban cards to precisely control information and material flow. Materials cannot be taken without a withdrawal Kanban card, and production cannot start without a production Kanban card.
The FMEA chart is a structured table where teams record all possible failure modes, their causes, effects, and the actions needed to minimize or prevent potential failures. It helps prioritize risks by assigning a Risk Priority Number (RPN) to each failure mode, which is the primary outcome of the FMEA exercise.
In FMEA, rating tables are used to assign numerical scores to the severity, occurrence, and detection attributes to ensure a consistent and objective assessment of failure modes. These numerical scores are used to calculate the RPN values, which help identify and prioritize the most critical risks.
