Kaizen Steps

Kaizen Team

Before Event

  1. Define SMART Goal, aggressive but achievable
  2. Within the Kaizen include a 5s workshop and improve two safety related issues (recommendation)
  3. Collect data
  4. Prepare service departments to provide quick service during the event: Purchasing and Maintenance

Event:

  1. Provide training to the team, regularly 3-4 hours in Kaizen meaning and basic tools
  2. Review Project Charter
  3. Develop a process map
  4. 5s Pre-audit
  5. Establish a Baseline
  6. conduct analysis and brainstorming
  7. Select solutions using the impact/difficulty matrix
  8. complete the 5s workshop
  9. Implement solutions (Focus on complete at least 70% of the activities during the event)
  10. 5s post audit
  11. Kaizen newspaper
  12. Prepare presentation and present to management (Team recognition)
  13. Present to rest of people from the area who did not participate in the Kaizen for understanding and care of the improvements
  14. Follow up Kaizen newspaper activities until completion
  15. Close the project

Training Content

  1. Fish Video (Enjoy the workshop)
  2.  Kaizen definition
  3. Project Charter
  4.  Baseline
  5. Brainstorming rules
  6. Ishikawa diagram
  7. Pareto Charts
  8. 8 wastes
  9. Takt time
  10. Impact difficulty Matrix
  11.  SOPs
  12. Before/After chart
  13. Additional training suggested: 5s training
  • No more than 10 people
  • Multifunctional Team
  • From process
  • From maintenance
  • From quality
  • Manufacturing Engineer or/and Supervisor
  • During the Kaizen working hours, the entire team will be relieved from any other regular activities
  • Team will present the results at the end of the event to management

Key Factors

  • All Improvements follow the PDCA Cycle. 
  • Look for waste elimination
    • DOWNTIME
    • Delays
    • Overproduction
    • Waiting
    • Not Utilized Talent
    • Inventory
    • Motion
    • Extra processing 
  • At least 30% of the team should be from the production floor

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