Short overview of Continuous Improvement/Kaizen and how to implement it.

1. CONTINUOUS IMPROVEMENT
and KAIZEN
By Julian Kalac
Lean Six Sigma Master Black Belt
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2. Continuous improvement “CI”
• Continuous improvement “CI” is an ongoing effort
to improve products, services or processes.
• These efforts can seek “incremental”
improvement over time or “breakthrough”
improvement all at once.
• "continuous improvement is a never-ending
change, where feedback from the process and
customer are constantly evaluated against
organisational goals
• Put simply, it means ‘getting better all the time’
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3. KAIZEN
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4. KAIZEN
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5. MY DEFINITION OF KAIZEN
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6. INSANITY “Doing the
same thing over and
over again and expecting
different results”
Albert Einstein
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8. Change Cycle
How people feel
Keep momentum
moving
MOST CRITICAL
TIME IN CHANGE
After results from
changes are seen
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9. How do you implement CI?
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10. Plan Do Study/Check Act (PDSA)
“Thinking” and Problem Solving Model
PDSA Cycle:
Plan, Do, Study, Act
 Plan a step
 Take a step
 Study the outcome
 What worked?
 What didn’t
work?
 What did we
learn?
 Act on the difference between
what you expected & what you
got
 Keep learning
This Way:
Plan
Do
Act
Check
Plan
Do
Re-Act
Check
Not this Way:
Dr Edwards Demming:
Lack of knowledge…
that is the problem
There is no substitute
for knowledge
Study
Analyze
Study
Analyze

11. HOW TO IMPLEMENT CI/KAIZEN?
Develop cross functional teams, Identify
problems that have biggest impact on business
Set target KPI metrics benchmark
Train everyone to understand why/what change
is needed, how to do it , i.e. Kaizen/CI PDCA, LSS.
Utilize tribal knowledge, engage front line
workers to develop improvement plans that are
effective and sustainable as a team
Implement improvements, validate effectiveness
implement control plans, all through team work
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