Short kaizen orientation
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This document discusses the stages and process of a Kaizen event. It begins by defining what a Kaizen is and explaining the typical stages: planning and preparation, the event itself, reporting out results, and follow up. The planning stage involves setting goals, selecting a team, collecting baseline data, and planning support. During the event, the standard work process is documented, improvement opportunities are identified and countermeasures planned. Results are measured and changes are verified and standardized. Follow up ensures improvements are sustained over time through continued reviews and assessments.
Short kaizen orientation
- 1. QMPD
- 2. Content: • What is a Kaizen? • Why Kaizen? • Stages of Kaizen • Planning and Preparation • Event • Report out • Follow-up
- 3. Why Kaizen?
- 4. Content: • What is a Kaizen? • Why Kaizen? • Stages of Kaizen • Planning and Preparation • Event • Report out • Follow-up
- 5. Planning and Preparation There are 4 basic steps: • Set goals. • Select the team. • Collect baseline data. • Plan to support the Kaizen activity.
- 6. Set Goals to reduce ventilator associated pneumonia from 30 per 1000 ventilator days to be below 10 per 1000 ventilator days
- 7. Select the Team • Team size should be based on the area(s) being kaizened. • A trained Facilitator and a Team Leader for each Team • Every team member should be chosen for a specific reason •Management •“Different Set of Eyes” •Customers and Suppliers (internal or external) •Experts (people who actually do the work) •Change Agents and “CAVE Men”
- 8. Data collection • We need objective evaluation of the process before and after the improvement so what will we do We collect data
- 9. Data collection What we will collect ??? • Base line data before initiation of the project: process as it is collect data of the current status • Results after Improvement: collect base line data and compare to know the project effectiveness. How will we collect it ??? • Data Sheet or Work Sheet: Form for recording data requires subsequent processing for analysis and interpretation. • Checklists: Form for recording data; designed to facilitate interpretation directly from form • Survey: Form for getting input from a large group
- 10. How do we present it 10,580 8,773 4,4145,030 6,768 4,420 CRP VIT-D HBA1C 2016 2017 71 63 53 7 8 8 9 8 7 JAN FEB MAR APR MAY JUN JUL AUG SEP BREAST FEEDING MOTHERS STATUS rejection 82% 91% 75% 80% 85% 90% 95% Before After % of compliance to antibiotic…> 11 days 16% < 12 days 84%
- 11. Plan to Support Kaizen • Top management support to cover Kaizen needs • Set clear goals and expectations with time frames • Empower employee While the goal of a Kaizen is to work around the process, interruptions are inevitable as improvements are implemented. Success requires action prior to the Kaizen. Items to consider:
- 12. Content: • What is a Kaizen? • Stages of Kaizen • Planning and Preparation • Event • Report out • Follow-up
- 13. The Standard Work elements of a Kaizen are: Document Reality Plan Countermeasures Identify Waste Reality Check Make Changes Verify Change Measure Results Make this the Standard Celebrate Do It Again Results: A new way of work Start Stages of the Kaizen
- 15. Content: • What is a Kaizen? • Stages of Kaizen • Planning and Preparation • Event • Report out • Follow-up
- 16. After the kaizen, the focus must be placed on ensuring that the improvements continue. This is done by: • Regular reviews by. GEMBA • walkthroughs • assessments Follow-up
- 17. 5S
- 18. “You never get a second chance to create a first impression.” First Impressions
- 19. 5S 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order (store) - A place for everything and everything is in its place 3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or dangerous conditions
- 20. SORT NECESSARY UNNECESSARY CATEGORIZE NECESSARY ITEMS: * RARELY USED * OCCASIONALLY USED * FREQUENTLY USED RED TAG STRATEGY ATTACH TO ALL UNNECESSARY ITEMS DISCARD UNNECESSARY ITEMS RED TAG Category 1. Raw material 6. Dies and jigs 2. In-process stock 7. Tools and supplies 3. Semi-finished goods 8. Measuring devices 4. Finished goods 9. Documents 5. Equipment 10.Other Item name and number Quantity Units $ Value Reason 1. Not needed 6. Other 2. Defective 3. Not needed soon 4. Scrap material 5. Use unknown Disposal by: Department/Business Unit/Product Center Disposal method: 1. Discard 2. Return 3. Move to red-tag storagesite 4. Move to separatestorage site 5. Other Disposal complete (signature ) Posting date: Disposal date: 9
- 21. Sort Item Frequent use Daily use Weekly use Monthly use
- 22. Store VISUAL LOCATIONS PW2000 FIXTURES 2A4397 3A9674 2B4659 IDENTIFICATION LINES DETERMINE LOCATION FOR NEEDED ITEMS CUTTER INSERTS 124GF 2HJF 12HJF 12HJF 12HJF 12HJF12HJF 12HJF 12HJF 12HJF 12HJF 12HJF12HJF 12HJF POINT OF USE STORAGE 13
- 23. SHINE CLEAN SWEEP CLEANING AS A FORM OF INSPECTION BUILD PRIDE IN WORK AREAS BUILD VALUE IN EQUIPMENT ELIMINATE DIRT 17
- 24. Check Item Consistent with the entire system Visual aids or visual control systems Visual Workplace Action Follow 5S Audit Sheet and all other visual controls Perform regular, scheduled audits Submit improvement suggestions Stick to the guidelines Produce signs, charts, graphs, paint equipment, color coding systems Implement standard method for cleaning and maintenance Create an environment in which anyone can know in five minutes or less the who, what, when, how and why of any work area: Without talking to anyone, without opening a file drawer, without opening a book or without turning on a computer 5S Guidelines 5S Review Schedule
- 25. PROPER TRAINING CORRECT PROCEDURES BECOME A HABIT SUSTAIN MANAGERS COMMITTED TO 5S 5 Sasdfsdfs sdf sdf dsfsdfsdfsfdsdfsdf “BUY-IN” FROM ALL WORKERS 27
- 26. The Good, Bad and the Ugly First the Bad and the Ugly - Life Without 5S
- 27. The Good
- 28. Any Questions?