Kaizen (What is it ?

)
Lean Foundations Continuous Improvement Training

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Continuous Improvement Process

Define

Six Sigma Project

Measure

Kaizen event 5S event

Analyze

Improve

I T A RAV I

Control

Problem solving
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ET SA W

Workplace organization

Rapid Implementation of Known Solution

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, coworkers 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

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