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© Operational Excellence Consulting. All rights reserved.
Guide for
Planning &
Conducting
a Kaizen Event
© Operational Excellence Consulting. All rights reserved. 2
Contents
• Introduction
• Phase 1: Pre-event Preparation
• Pha...
© Operational Excellence Consulting. All rights reserved.
INTRODUCTION
1
© Operational Excellence Consulting. All rights reserved. 4
What is Kaizen?
• The Japanese word “Kaizen” (改 善) means
chang...
© Operational Excellence Consulting. All rights reserved. 5
What is Kaizen?
• Kaizen means improvement. Improvements
witho...
© Operational Excellence Consulting. All rights reserved. 6
What is the Purpose of Kaizen?
• Kaizen activities focus on ea...
© Operational Excellence Consulting. All rights reserved. 7
What is a Kaizen Event?
• A Kaizen event is a rapid, focused a...
© Operational Excellence Consulting. All rights reserved.
PRE-EVENT
PREPARATION
2
© Operational Excellence Consulting. All rights reserved. 9
Select an Area
• Choose an area that will have an impact but n...
© Operational Excellence Consulting. All rights reserved. 10
Select a Problem for Improvement
• Desirable selection criter...
© Operational Excellence Consulting. All rights reserved. 11
Select a Team Leader
• “Leader” is not “supervisor”
• Prefera...
© Operational Excellence Consulting. All rights reserved. 12
Select the Team Members
• 4 to 10 people
• From across all le...
© Operational Excellence Consulting. All rights reserved. 13
Facilities and Logistics
• Work Areas
 Notify people of upco...
© Operational Excellence Consulting. All rights reserved. 14
Collecting Information
• Concentrate on ‘the what’ rather tha...
© Operational Excellence Consulting. All rights reserved.
THE
KAIZEN EVENT
3
© Operational Excellence Consulting. All rights reserved. 16
Kaizen Event Process
1. Orientation
2. Understand
Current Sit...
© Operational Excellence Consulting. All rights reserved. 17
Kaizen Event Agenda*
Day 1 –
Orientation
• Welcome &
Introduc...
© Operational Excellence Consulting. All rights reserved.
Day 1 –
Orientation
© Operational Excellence Consulting. All rights reserved. 19
Orientation
• Welcome and introduce the Kaizen team
• Set exp...
© Operational Excellence Consulting. All rights reserved. 20
Identify the Customer
• Value added is always determined from...
© Operational Excellence Consulting. All rights reserved. 21
Safety & Integrity
• All event activities must be performed w...
© Operational Excellence Consulting. All rights reserved. 22
Code of Conduct
• Keep an open mind
• Maintain a positive
att...
© Operational Excellence Consulting. All rights reserved. 23
Team Orientation
• Team member package
 Agenda
 Background ...
© Operational Excellence Consulting. All rights reserved. 24
Kaizen Event Charter
Event Name:
Process name and location:
P...
© Operational Excellence Consulting. All rights reserved.
Day 2 –
Understand
current situation
© Operational Excellence Consulting. All rights reserved. 26
Understand Current Situation
• Crucial first step in process ...
© Operational Excellence Consulting. All rights reserved. 27
Value Stream Map
• Visual depiction of a complete value strea...
© Operational Excellence Consulting. All rights reserved. 28
Identify VA, NVA-R, and NVA
Necessary
to Produce
Output?
Adds...
© Operational Excellence Consulting. All rights reserved.
Day 3 –
Develop future
state design
© Operational Excellence Consulting. All rights reserved.
Day 4 –
Make the
improvements
© Operational Excellence Consulting. All rights reserved.
Day 5 –
Report &
celebrate
© Operational Excellence Consulting. All rights reserved.
POST-EVENT
FOLLOW-UP
4
© Operational Excellence Consulting. All rights reserved.
www.oeconsulting.com.sg
END OF PREVIEW
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Kaizen Event Guide by Operational Excellence Consulting

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A Kaizen Event/Blitz (a.k.a. Rapid Improvement Event) is a rapid, focused application of Lean methods to reduce waste so as to improve cost, quality, delivery, speed, flexibility and responsiveness to internal/external customer needs. For a Kaizen event to be effective, it has to be well planned and executed.

This presentation guide provides a step-by-step guidance to the planning, preparation and conducting a Kaizen Event.​ It includes post-event follow up activities as well as templates for Kaizen charter and presentation to management and other stakeholders.

CONTENTS

Introduction
- What is Kaizen?
- 10 rules of Kaizen
- What is the purpose of Kaizen?
- Value
- Types of waste
- What is a Kaizen event?
- Benefits of Kaizen and Kaizen events

Phase 1: Pre-event Preparation
- Select an area
- Select a problem for improvement
- Common projects for Kaizen events
- Setting goals
- Select team leader
- Team leader role
- Select team members
- Facilities and logistics
- Collecting information
- Preparing the area, materials and resources
- Conference room or Gemba?
- Pre-event communications
- Tips for success
- Kaizen event rules

Phase 2: The Kaizen Event
- The Kaizen event/blitz
- The Kaizen process
- Kaizen event agenda
- How to conduct a 5S Kaizen event
- Orientation
- Understand current situation
- Develop future state design
- Make the improvements
- Report out and celebrate

Phase 3: Post-event Follow Up
- Follow up with event sponsor/champion and event leaders
- Tracking progress against performance goals
- Project review and closing out
- Publish follow-up communication

Appendices
- Kaizen event templates
- Kaizen event presentation templates

To download this complete presentation, please go to: http://www.oeconsulting.com.sg

Published in: Business, Education, Technology
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  • DOWNLOAD THAT BOOKS INTO AVAILABLE FORMAT (2019 Update) ......................................................................................................................... ......................................................................................................................... Download Full PDF EBOOK here { http://bit.ly/2m6jJ5M } ......................................................................................................................... Download Full EPUB Ebook here { http://bit.ly/2m6jJ5M } ......................................................................................................................... Download Full doc Ebook here { http://bit.ly/2m6jJ5M } ......................................................................................................................... Download PDF EBOOK here { http://bit.ly/2m6jJ5M } ......................................................................................................................... Download EPUB Ebook here { http://bit.ly/2m6jJ5M } ......................................................................................................................... Download doc Ebook here { http://bit.ly/2m6jJ5M } ......................................................................................................................... ......................................................................................................................... ................................................................................................................................... eBook is an electronic version of a traditional print book that can be read by using a personal computer or by using an eBook reader. (An eBook reader can be a software application for use on a computer such as Microsoft's free Reader application, or a book-sized computer that is used solely as a reading device such as Nuvomedia's Rocket eBook.) Users can purchase an eBook on diskette or CD, but the most popular method of getting an eBook is to purchase a downloadable file of the eBook (or other reading material) from a Web site (such as Barnes and Noble) to be read from the user's computer or reading device. Generally, an eBook can be downloaded in five minutes or less ......................................................................................................................... .............. Browse by Genre Available eBooks .............................................................................................................................. Art, Biography, Business, Chick Lit, Children's, Christian, Classics, Comics, Contemporary, Cookbooks, Manga, Memoir, Music, Mystery, Non Fiction, Paranormal, Philosophy, Poetry, Psychology, Religion, Romance, Science, Science Fiction, Self Help, Suspense, Spirituality, Sports, Thriller, Travel, Young Adult, Crime, Ebooks, Fantasy, Fiction, Graphic Novels, Historical Fiction, History, Horror, Humor And Comedy, ......................................................................................................................... ......................................................................................................................... .....BEST SELLER FOR EBOOK RECOMMEND............................................................. ......................................................................................................................... Blowout: Corrupted Democracy, Rogue State Russia, and the Richest, Most Destructive Industry on Earth,-- The Ride of a Lifetime: Lessons Learned from 15 Years as CEO of the Walt Disney Company,-- Call Sign Chaos: Learning to Lead,-- StrengthsFinder 2.0,-- Stillness Is the Key,-- She Said: Breaking the Sexual Harassment Story That Helped Ignite a Movement,-- Atomic Habits: An Easy & Proven Way to Build Good Habits & Break Bad Ones,-- Everything Is Figureoutable,-- What It Takes: Lessons in the Pursuit of Excellence,-- Rich Dad Poor Dad: What the Rich Teach Their Kids About Money That the Poor and Middle Class Do Not!,-- The Total Money Makeover: Classic Edition: A Proven Plan for Financial Fitness,-- Shut Up and Listen!: Hard Business Truths that Will Help You Succeed, ......................................................................................................................... .........................................................................................................................
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Kaizen Event Guide by Operational Excellence Consulting

  1. 1. © Operational Excellence Consulting. All rights reserved. Guide for Planning & Conducting a Kaizen Event
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Contents • Introduction • Phase 1: Pre-event Preparation • Phase 2: The Kaizen Event • Phase 3: Post-event Follow Up NOTE: As this is a PREVIEW, only selected slides are shown. To download the complete guidebook, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. INTRODUCTION 1
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 What is Kaizen? • The Japanese word “Kaizen” (改 善) means change (KAI) to become good (ZEN). 改 善 Change Good Kai Zen
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 What is Kaizen? • Kaizen means improvement. Improvements without spending much money, involving everyone from managers to employees, and using much common sense. • The aspect of Kaizen is that it is on-going and never-ending improvement process.
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 What is the Purpose of Kaizen? • Kaizen activities focus on each process in order to add value and eliminate waste
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 What is a Kaizen Event? • A Kaizen event is a rapid, focused application of Lean methods to reduce waste in particular areas of the shopfloor or office. • 3-5 day dedicated event • Clear objective and scope • Changes are implemented quickly • Everyone gets involved Source: "The Idea Generator” by Norman Bodek
  8. 8. © Operational Excellence Consulting. All rights reserved. PRE-EVENT PREPARATION 2
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 Select an Area • Choose an area that will have an impact but not pose too many difficult problems in the beginning • Each event will teach you things that will make the next event smoother and easier to run • As people gain experience in running events, it will become possible to tackle more complicated problems • Develop a selection criteria to select the best event to start first
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 Select a Problem for Improvement • Desirable selection 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
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 Select a Team Leader • “Leader” is not “supervisor” • Preferably has experience with the Kaizen process • Should be biased toward change and open- minded • Should not be dictatorial in leadership style • Be able to take control when necessary
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 Select the Team Members • 4 to 10 people • From across all levels and functions impacted by the project • Include experts – if they have open minds • Include people with prior Kaizen experience • Include outsiders from unrelated functions to obtain different points of view • Provide focused training to the team before the event
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 Facilities and Logistics • Work Areas  Notify people of upcoming Kaizen and purpose  Floor/equipment layout – obtain/create a schematic • Training / Meeting Rooms  Reserve room  Flipcharts, overhead projector, Post-it® notes, etc. • Food and Refreshments • Location for Celebration
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 Collecting Information • Concentrate on ‘the what’ rather than ‘the how’ of doing a Kaizen • Information to be collected may include:  Standard Operating Procedures, Policies  Shop-floor/Lab/Office Layout and Flow (create a ‘spaghetti diagram’)  Job Descriptions, Skills/Knowledge Matrix  Errors – Quantity and Type
  15. 15. © Operational Excellence Consulting. All rights reserved. THE KAIZEN EVENT 3
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 Kaizen Event Process 1. Orientation 2. Understand Current Situation 3. Develop Future State Design 4. Make the Improvements 5. Report & Celebrate
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 Kaizen Event Agenda* Day 1 – Orientation • Welcome & Introductions • Set expectations • Provide focused training • Identify the Customer • Define Kaizen Charter Day 2 – Understand current situation Day 3 – Develop future state design Day 4 – Make the improvements Day 5 – Report & celebrate MorningAfternoon Lunch • Document current state – process map or value stream map, identify waste (opportunities), data collection, etc. • Establish current state • Day 1 summary • Set objective(s) for Day 2 • Analyze current state • Brainstorm ideas • Root cause analysis • Prioritize solutions • Future state design • Analyze current state • Brainstorm ideas • Root cause analysis • Prioritize solutions • Future state design • Day 2 summary • Set objective(s) for Day 3 • Future state design • Mid-week review • Implement improvements • Implement improvements • Try out or simulate new process • Train participants • Tweak design as needed • Day 3 summary • Set objective(s) for Day 4 • Implement improvements • Try out or simulate new process • Train participants • Tweak design as needed • Create and implement standard work • Measure future state • Calculate actual benefits • Day 4 summary • Set objective(s) for Day 5 • Finalize future state • Complete training on standard work • Final presentation • Lunch & celebration * Adjust duration as required
  18. 18. © Operational Excellence Consulting. All rights reserved. Day 1 – Orientation
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 Orientation • Welcome and introduce the Kaizen team • Set expectations – what is the objective? • Provide focused training, e.g. Kaizen overview, VSM  Limit to half a day maximum • Identify the Customer – internal/external • Define the Kaizen charter
  20. 20. © Operational Excellence Consulting. All rights reserved. 20 Identify the Customer • Value added is always determined from the customer’s perspective • Who is the customer? • Every process should be focused on adding value to the customer • Anything that does not add value is waste • Some non-valued added activity is necessary waste (“NVA-R”)  Regulatory  Legal
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 Safety & Integrity • All event activities must be performed with your safety and the public safety in mind • Take the opportunity to correct hazards, even if not directly tied to the event • Process changes must not lower the quality of products/services • Consider ergonomics and focus on reducing waste when redesigning a job/process
  22. 22. © Operational Excellence Consulting. All rights reserved. 22 Code of Conduct • Keep an open mind • Maintain a positive attitude • Never leave a silent disagreement • Create a blameless environment • Practice mutual respect • Every voice counts • No dumb questions • No magic wands, just proper training and a drive to working smarter • Be guided by this thought …‘just do it, now!’ • Allow no hand grenades (no hidden agendas)!
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 Team Orientation • Team member package  Agenda  Background data  Objectives  Rules and safety procedures  Kaizen Charter  Policies & Procedures • Review the process • Clear, simple priorities • Goals and work requirements, hours, start time, daily meetings • Deadlines, milestones • Avoiding conflicts • Roles for management
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 Kaizen Event Charter Event Name: Process name and location: Problem statement: Event Objectives: Event Metrics: Team members: Process owner: Champion: Potential Roadblocks:
  25. 25. © Operational Excellence Consulting. All rights reserved. Day 2 – Understand current situation
  26. 26. © Operational Excellence Consulting. All rights reserved. 26 Understand Current Situation • 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 or define the value stream
  27. 27. © Operational Excellence Consulting. All rights reserved. 27 Value Stream Map • Visual depiction of a complete value stream (Material and Information Flow) where waste and customer value can be identified and action plans are created.
  28. 28. © Operational Excellence Consulting. All rights reserved. 28 Identify VA, NVA-R, and NVA Necessary to Produce Output? Adds Value to Customer? Non-Value Added Sustaining Customer Value Added Yes Yes No NoYes Activity No Agree Specifications Manufacturing VA NVA-R NVA Contributes to Business Effectiveness? Payroll Testing Development Activity Back-up Database Changeovers Audits Regulatory Review & Approval Scrap Rework Filing Copying Reconciliation
  29. 29. © Operational Excellence Consulting. All rights reserved. Day 3 – Develop future state design
  30. 30. © Operational Excellence Consulting. All rights reserved. Day 4 – Make the improvements
  31. 31. © Operational Excellence Consulting. All rights reserved. Day 5 – Report & celebrate
  32. 32. © Operational Excellence Consulting. All rights reserved. POST-EVENT FOLLOW-UP 4
  33. 33. © Operational Excellence Consulting. All rights reserved. www.oeconsulting.com.sg END OF PREVIEW To download this complete presentation, please visit:

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