Kaizen Event Guide by Operational Excellence Consulting


Presentation Description

A Kaizen Event is a rapid, focused application of Lean to reduce waste so as to improve cost, quality, delivery, speed, flexibility and responsiveness to internal/external customer needs. 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. This event guide can be used together with the Kaizen PowerPoint training presentation. To download this presentation, please go to: http://www.oeconsulting.com.sg


Presentation Transcript

Guide for Planning & Conducting a Kaizen Event:

Guide for Planning & Conducting a Kaizen Event


Contents A Kaizen Event can be conducted in three phases as follow: Phase 1: Pre-event Preparation Phase 2: 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



Select an Area:

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

Select a Problem for Improvement:

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

Common Projects for Kaizen Events:

Common Projects for Kaizen Events Good Housekeeping (“5S”) Waste (“ Muda ”) Elimination Standardization Kaizen

Setting Goals:

Setting Goals Set a limited number of improvement goals to be achieved during the event Prioritize multiple objectives Use S.M.A.R.T. criteria for goal setting: S =Specific; M =Measurable; A =Achievable; R =Realistic; T =Timely Goals should be challenging – requiring real creativity Team should be involved in setting improvement targets Objectives may not be completely met

Select a Team Leader:

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

Pre-Event Communications:

Pre-Event Communications Communication from Leadership should: Explain to employees what a Kaizen Event is and why it is needed Explain how it supports Lean initiatives Focus on long-term improvement rather than short-term disruption Discuss safety and ergonomic concerns Set expectations for step change, not insignificant incremental improvement When people are familiar with the Event prior to its occurrence, they will be more receptive and productive during the Event

Kaizen Event Rules:

Kaizen Event Rules Be open to change Stay positive Speak out if you disagree See waste as an opportunity No blame environment Treat others as you want to be treated Ask the silly questions, challenge the givens Creativity before capital Understand the data and principles Just do it!

Pre-event Preparation Checklists:

Pre-event Preparation Checklists

Three Weeks Before Event…:

Three Weeks Before Event… Decide with Executive Sponsor: Event Topic & Background What opportunities exist to solve in the event Why do they exist Scope of the Kaizen/Project Critical Success Factors Objective Define (reduction percentage, improvement required, $ savings target, cycle time (TAT) improvement) Define Customers and their requirements/needs/expectations Deliverables stated in S. M. A. R. T. Goal terms: Benefits: State them to guide Team of the expectations from Event Send out communication regarding upcoming event to staff Decide team m embers: E xpertise; Potential to contribute; Location; A vailability; Full-time vs. when needed or by phone

Day of Event…:

Day of Event… Arrive Early – One hour before start of Event Make final preparations to the room Setup computer and projector Tape flipchart paper together for Value Stream Mapping exercises as-is/current state VSM to-be/future state VSM Create Name Tents for participants (if needed), or participants can write their names on Post-It notes and paste on their shirts/tops Display Daily Agenda on flipchart paper Display ‘Issues’, ‘Quick Wins’, ‘Parking Lot’, ‘Barriers’ each on a separate flipchart paper taped on the wall



Kaizen Event Process:

Kaizen Event Process

Kaizen Event Agenda*:

Kaizen Event Agenda* Day 1 – Set the scene Welcome & Introductions Set expectations Provide focused training Identify the Customer Define Kaizen Charter Day 2 – Understand current process Day 3 – Develop future state design Day 4 – Implement solutions Day 5 – Report & celebrate Morning Afternoon Lunch Measure current s tate – 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

Day 1 – Set the scene:

Day 1 – Set the scene

Kaizen Event Process:

Kaizen Event Process

Set the Scene:

Set the Scene 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

Day 2 – Understand current process:

Day 2 – Understand current process

Kaizen Event Process:

Kaizen Event Process

Understand Current Process:

Understand Current Process 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

Value Stream Map:

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.

Day 3 – Develop future state design:

Day 3 – Develop future state design

Kaizen Event Process:

Kaizen Event Process

Develop the Future State:

Develop the Future State

Day 4 – Implement solutions:

Day 4 – Implement solutions

Day 5 – Report & celebrate:

Day 5 – Report & celebrate




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