freeleansite.com Kaizen (What is it ?) Lean Foundations Continuous Improvement Training Lean Foundations Continuous Improvement Training

freeleansite.com Measure Analyze Improve Control Define Continuous Improvement Process Six Sigma Project Kaizen event 5S event Workplace organization Rapid Implementation of Known Solution Problem solving VARIATIONVARIATION WASTEWASTE

freeleansite.com KAIZENKAIZEN 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.

freeleansite.com KAIZENKAIZEN 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

freeleansite.com KAIZENKAIZEN 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.

freeleansite.com KAIZENKAIZEN  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)

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

freeleansite.com KAIZENKAIZEN  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.

freeleansite.com 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

freeleansite.com 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

freeleansite.com KAIZEN Event Type of Projects?  What type of problem or issue might you utilize a Kaizen event for ?

freeleansite.com Kaizen (What is it ?) Lean Foundations Continuous Improvement Training Lean Foundations Continuous Improvement Training