Kaizen Sample
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The document provides an overview of Kaizen and the Kaizen Blitz continuous improvement process. It discusses selecting projects, setting goals, team roles, infrastructure support, potential roadblocks and the typical Kaizen steps of observing the current process, developing a future state process, implementing changes, and reporting results. Typical results of a Kaizen Blitz include 40-60% reduced lead times, 10-15% increased productivity, and 10-20% lower rework.
Kaizen Sample
- 1. Kaizen Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams
- 2. Contents © 2007 Superfactory™. All Rights Reserved. Introduction Background and History Components and Implementation How to Kaizen The Kaizen Blitz Roadblocks Knowledge Check
- 3. Introduction © 2007 Superfactory™. All Rights Reserved. Kaizen is a process of continuous incremental improvement. The “kaizen blitz” is a five-day continuous improvement activity focused on a very specific process.
- 4. Components and Implementation © 2007 Superfactory™. All Rights Reserved. Selecting Projects Setting Goals The Team and Team Leader Support and Infrastructure The Kaizen Blitz Potential Roadblocks Kaizen Steps Set the scene Observe the current process Develop the future state process Implement the new process Report and Analyze
- 5. Selecting Kaizen Projects © 2007 Superfactory™. All Rights Reserved. Desirable criteria for initial projects Unambiguously measurable Management enthusiasm A clear business need Highly visible process Fairly easy project Strong environment for follow-up Simple process Stable and repeatable process Allows contribution by all employees – not a technical exercise Self-contained process
- 6. Support and Infrastructure © 2007 Superfactory™. All Rights Reserved. Eliminate interruptions for team members No cell phones No visitors Dedicated conference room Eat together Supplies Flip charts White board Snacks Management support Team members have full support of management Responsibilities are covered to eliminate interruptions
- 7. Kaizen “Blitz” © 2007 Superfactory™. All Rights Reserved. Total focus on a defined process to create radical improvement in a short period of time Dramatic improvements in productivity, quality, delivery, lead-time, set-up time, space utilization, work in process, workplace organization Typically five days (one week) long
- 8. Observe the Current Process © 2007 Superfactory™. All Rights Reserved. Crucial first step in process improvement Deep understanding of the existing processes and dependencies Identify all the activities currently involved in developing a new product Observe the process first hand Flowchart the process Take measurements – time, yield, travel distance Identify Value Added (VA), Non-Value Added Required (NVA-R), and Non-Value Added (NVA) Generally creates more questions than answers
- 9. Develop the Future State © 2007 Superfactory™. All Rights Reserved.
- 10. Typical Results © 2007 Superfactory™. All Rights Reserved. 40 – 60% reduction of lead time 10 – 15% productivity improvement 10 – 20% reduction in rework Improved communication between functions and departments Clearly defined customer needs throughout the value stream Improved customer satisfaction