Free template
Updated
Daily kaizen routine board
Daily kaizen is the small, immediate improvement a team makes in its own area: no approval process, done the same day or within the shift. Repositioning a tool, fixing a label or adding a hook are typical. A daily kaizen routine makes it a habit: the team meets at its board for 10 to 15 minutes every day, each person brings one problem, the team picks one or two it can fix itself, and each fix gets one owner. Page 1 of this template is a week's board: two rows a day for the problem spotted, the small fix, the owner, the date done, the effect (time, quality, safety or other) and how much, and the days open, with the routine's time boxes, the week's count and the fix to share. Page 2 has the routine in seven steps, what counts as a daily kaizen, the weekly share-out and a worked example. The Excel version logs every fix, works out days open and a status against an open limit you set, and counts raised, done and open by week, effect and person, with a chart.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for team, week, board leader and routine time, an effect key, a board with two rows for each day from Monday to Friday plus two extra (problem spotted, small fix, owner, done date, effect, how much, days open), the routine's time boxes, the week's count and a box for the fix to share.A week's board10 to 15 minute routineSmall fix, one ownerEffect: time, quality, safetyDays openWeek's countWeekly share-outSeven steps
When to use it
When to use a daily kaizen routine board
- When improvement only happens at kaizen events, and small problems wait weeks for one.
- To start a team on continuous improvement with something it can do every day in a few minutes.
- When the same small annoyances come up at every huddle and nobody owns them.
- To show, week by week, how many small fixes a team makes and what they changed.
How to fill it in
- 1
Set the time and the board
Pick 10 to 15 minutes at the start of the shift, standing at the team's board, and keep the time box. Fill in the team, the week and the board leader.
- 2
Check yesterday's fixes first
For each fix on the board, write the date done and the effect, or say what is stopping it. If a fix did not work, try again or take it further.
- 3
One problem from each person
Something that slowed them down, risked a defect or an injury, or annoyed them since yesterday. Write what and where in the day's row.
- 4
Pick one or two, give each one owner
Choose the problems the team can fix itself today, in its own area, with no approval beyond what the site lets a team decide. Write the small fix and one name. The rest go to the idea system or the supervisor.
- 5
Count the effect
Circle time, quality, safety or other and write how much: minutes a day, defects, a risk removed. A fix with no number still counts. Days open is the date done minus the day raised.
- 6
Share once a week
Count raised, done and open, move any fix open past the team's limit to the supervisor or the idea system, and show one fix to another shift or team.
What's on the board
What counts as a daily kaizen, and the weekly share-out
Four tests a problem must pass to be fixed on the board, and five things to do at the weekly share-out. They are on page 2 and on the Excel version's Rules sheet.
What counts as a daily kaizen
All four, or it goes to the idea system or a bigger project
- 1The team can make the change in its own area, today or this shift
- 2It needs no approval or budget beyond what the site lets a team decide
- 3It is safe to do, and changes to guards, electrics or a quality standard go to their owner first
- 4It removes something real: lost time, a defect risk, a safety risk or a daily annoyance
Weekly share-out
Five minutes, once a week, at the same board
- 5Count the fixes raised, done and still open
- 6The owner of each open fix says what is stopping it
- 7Fixes open past the team's limit go to the supervisor or the idea system
- 8Pick one fix to show another shift or team
- 9Thank the people behind the fixes by name
A filled-in example
Illustrative, not a benchmarkAn example: assembly cell 3 runs the routine at 07:00 for the week of 21 September 2026; the status is as of Friday 25 September (illustrative).
The example week on the board
- Fixed the same day: 5 problems
- Fixed the next day: 3 problems
- Open: 2 problems
- Spare scanner battery10 min a day
- Label roll holder6 min a day
- Kanban card holder at eye level4 min a day
10 problems raised: 5 fixed the same day, 3 fixed the next day, 2 open. Three timed fixes save 6, 10 and 4 minutes a day, 20 in all.
- Ten problems were raised in five days, two a day: a torque gun cable catching on the fixture, walking to the shelf for labels, a scanner battery dying mid-shift, gloves too big for small parts and six more.
- Eight were fixed, five of them the same day. The label roll holder was raised Monday and fitted Tuesday, 1 day open; the 8 done fixes took 0, 1, 0, 1, 0, 1, 0 and 0 days, 3 ÷ 8 = 0.4 days on average.
- Three fixes were timed: the label holder saves 6 minutes a day, the spare scanner battery 10 and the kanban card holder at eye level 4, so 6 + 10 + 4 = 20 minutes a day.
- Two are open: an oil drip at the press feed has a drip tray as a stopgap while maintenance repairs the leak on a work order, and a longer air hose waits for stores.
The week's count: 10 raised, 8 done, 2 open, 0.4 days to done on average, 20 minutes a day saved, five people with a fix. At Friday's share-out the team showed the spare scanner battery to the other two shifts.
Common mistakes
Turning the routine into a meeting
Past 15 minutes people stop coming. Problems that need discussion go to the idea system, the supervisor or a separate session.
Fixes with no owner
A fix written on the board with two names or a team name waits. One person owns it, even if others help.
Taking on problems too big for a day
A daily kaizen is small and in the team's own hands. A machine repair, a layout change or a new process step belongs in a work order, a quick kaizen or a kaizen event.
Counting ideas, not fixes
The board is for changes made, not suggestions collected. Count what is done and what changed, and chase what stays open.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite operators submit an idea from the shop floor on the mobile app with a photo, a reviewer approves it, and an approved idea gets an implementor and is marked complete or becomes a Kaizen project, with reports on participation and the average time to implement.
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FAQ
Daily kaizen routine board: common questions
Small, immediate improvements made by operators or supervisors in their own area, with no approval process, done the same day or within the shift. Moving a tool, fixing a label or adding a hook are typical. A daily routine at the team's board makes it a habit.
Ten to fifteen minutes at the board, standing. The template splits it into checking yesterday's fixes, one problem from each person, picking one or two to fix today, and passing anything bigger on. Keep the time box so it lasts.
A Just Do It card records one quick fix, and a quick kaizen sheet writes up one improvement that took a few days. The daily kaizen board is the team's daily habit: the problems raised each day, who owns each fix, how long it stays open and the weekly count. A kaizen action tracker follows actions from events and meetings with due dates; this board is for fixes the team makes itself the same day.
They leave the board. A suggestion that needs approval goes to the idea system, a problem that needs a few days of work to a quick kaizen, a machine repair to a maintenance work order and an area-wide change to a kaizen event. The Excel version flags any fix open past the limit the team sets.
Count the fixes raised, done and still open each week, the days from raised to done, and the effect: minutes a day where someone timed it, defects or a risk removed. Count fixes made, not ideas collected, and look at the trend over weeks rather than one week.
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- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.