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Kaizen Breakthrough
Kaizen Breakthrough is a five-day team-based process for rapid improvement focused on bias for action, creativity before capital, and achieving end-of-week results. The process follows the PDCA methodology and concentrates on learning by doing, overcoming resistance, and instilling a Kaizen culture. Key principles include establishing clear objectives and a charter before starting, involving associates and key resources, focusing tightly on the five-day timeframe, implementing quick and simple improvements, achieving immediate action with a new functioning process by the end of the week, and documenting results. Each day of the five-day flow has specific activities, such as developing the charter, running time studies, implementing changes, verifying improvements, and documenting the
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Kaizen Breakthrough
- 2. ▪ What isKaizen Breakthrough? ▪ Steps to Follow.
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- 5. Methodology (PDCA) A five-dayteam based process for rapid improvement focused on: ▪ Bias For Action ▪ Creativity Before Capital ▪ End Of Week Results Concentrating on: ▪ Learn By Doing ▪ Overcoming Resistance ▪ Instilling Kaizen Culture Rapid Change Through Immediate Action! Kaizen Breakthrough
- 6. Kaizen Breakthrough Principles ▪ ClearObjectives – Charter (established before Kaizen). ▪ Team Based Activity – Involve associates and key resources. ▪ Tight Focus on Time (5-Days). ▪ Quick & Simple Improvements (use all 24 hours if necessary). ▪ Immediate Action (new process functioning by end of week). ▪ Document Project Results – “Before” & “After” Kaizen.
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- 8. Current State 'BeforeKaizen’ Matrix Kaizen Breakthrough
- 9. Kaizen Five-Day Flow KaizenBreakthrough DAY 1 Develop Charter Develop Takt Time Document “Before Kaizen“ Matrix Process Diagram
- 10. Kaizen Five-Day Flow KaizenBreakthrough DAY 2 Run Time Studies Capture Layouts Spaghetti Charts Capacity Table Waste Walk DAY 1 Develop Charter Develop Takt Time Document “Before Kaizen“ Matrix Process Diagram
- 11. Kaizen Five-Day Flow KaizenBreakthrough DAY 2 Run Time Studies Capture Layouts Spaghetti Charts Capacity Table Waste Walk DAY 3 Implement Changes Remove Constraints Run New Time Studies Implement New Tools Check Quality DAY 1 Develop Charter Develop Takt Time Document “Before Kaizen“ Matrix Process Diagram
- 12. Kaizen Five-Day Flow KaizenBreakthrough DAY 4 Run Improved Process Document Any Issues Verify Changes Are Positive Make Sure Line Flows DAY 2 Run Time Studies Capture Layouts Spaghetti Charts Capacity Table Waste Walk DAY 3 Implement Changes Remove Constraints Run New Time Studies Implement New Tools Check Quality DAY 1 Develop Charter Develop Takt Time Document “Before Kaizen“ Matrix Process Diagram
- 13. Kaizen Five-Day Flow DAY2 Run Time Studies Capture Layouts Spaghetti Charts Capacity Table Waste Walk DAY 3 Implement Changes Remove Constraints Run New Time Studies Implement New Tools Check Quality DAY 4 Run Improved Process Document Any Issues Verify Changes Are Positive Make Sure Line Flows DAY 5 Kaizen Breakthrough DAY 1 Develop Charter Develop Takt Time Document “Before Kaizen“ Matrix Process Diagram Develop New SOP’s Document “After Kaizen” Matrix Train All Associates Broadcast New Process Submit Project paperwork
- 14. Current State 'AfterKaizen’ Matrix Kaizen Breakthrough
- 16. ▪ Kaizen Charter– should be first page of project paperwork. ▪ Wastes Observed – list of waste observed on waste walk. - Calculate NVA/VA Ratio, Spaghetti Chart, Time Observations, Inventory Counts ▪ Before and After Layouts – show machines, people, product, WIP, etc. ▪ Process Capacity Table – captures manual and machine dependency. ▪ Kaizen Newspaper – list of activities that took place during the Kaizen. ▪ Document Project Results – 'Before' & 'After' Kaizen Matrix - Pictures, lots of pictures! Kaizen Report Out Note – these points are a guideline and not an all inclusive list.
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