Kaizen (What is it ?)

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Kaizen (What is it ?)

• Lean Foundations
• Continuous Improvement Training

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Continuous Improvement Process
Six Sigma Project
Kaizen event
VARIATION
WASTE
5S event
Workplace organization
Rapid Implementation of Known Solution
Problem solving
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KAIZEN

• WHAT IS IT
• Kaizen is a tool originally used by Toyota to
  foster continued improvement within its Toyota
  Production System.
• It began as "Quality Circles," a means of factory
  shop floor employees solving quality issues
  within a structured team framework, using
  specific new tools.
• It is now used around the world by many companies
  and has been adapted to suit their individual
  needs and customs.

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KAIZEN

• WHAT IS IT
• Kaizen in the United States usually refers to an
  event of from three to five days of intense
  improvement activities directed at a specific
  area of a business.
• It is a process based on improving Safety,
  Quality, and Delivery, by the elimination of
  waste (muda) in its many forms.
• Its main tools are the implementation of
• One Piece Flow
• Working to Takt Time
• Developing a Pull System

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KAIZEN

• WHAT IS IT
• Kaizen events are a way of accelerating
  improvements
• to improve worker productivity,
• helping management to find new ways to gain
  substantial savings in time, space and labor
  output.
• to collapse lead times,
• reduce work-in-process dramatically,
• reducing scrap and defects while minimizing the
  need for capital expenditures.

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KAIZEN

• A typical 3-5 day Kaizen events consists of
• Team training (1/2 day)
• Lean overview
• Structure of Kaizen event
• Team conducts Kaizen on the factory floor / area
• (2-1/2 to 3-1/2 days)
• Identifying problems
• Defining current process
• Observing, sketching process and collecting data
• Brainstorming suggestions for improvement
• Implementing solutions (Rearrange equipment,
  Modify machines, change methods, etc)

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KAIZEN

• Team measures improvements and verifies solutions
  (1/2 day)
• Team presents results to management, co-workers
  and shop floor personnel (1/4 day)

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KAIZEN

• Kaizen is a way of unlocking the talents and
  abilities of workers and allow decisions to be
  made
• at the operating level in the organization,
• in the quickest time,
• by the people that know the situation the best.

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KAIZEN Event

• Type of Projects
• Eliminate long conveyor assembly lines with cells
• Combine operations
• Reduce setup times - SMED
• Reduce lot sizes, reduce WIP
• Determine proper tooling needed and organize
• Visual factory
• 5S only
• Establish new metrics
• Load level schedule
• Implement new product

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KAIZEN Event

• Type of Projects
• Increase or decrease production based on new takt
  time
• Change the process
• Change from automated process to manual
• Move from one location to another
• Safety Improvements
• Maintenance Programs or machine overhaul
• Process improvement

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KAIZEN Event

• Type of Projects?
• What type of problem or issue might you utilize a
  Kaizen event for ?

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Kaizen (What is it ?)

• Lean Foundations
• Continuous Improvement Training