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LEAN and KAIZEN BLITZ


Any Lean Deployment must be based upon the Pull System. Since each organization’s processes are unique and the scope and boundaries of each program varies, specific focus should be placed on each Product/Service Delivery System.

Organizations must Pull from their uniquely tailored Lean Toolbox to support the capability of each process. The Voice of the Customer and the Voice of the Process will dictate the application of Lean Strategies, Tools and Methods throughout your Enterprise’s Value Streams.

PROCESS KAIZEN
5 Day Workshop:Process Kaizen - Improvements made at an individual process or in a specific area.

Kaizen - Continuous, incremental improvements of an activity to create more Value with less Waste.

PROCESS KAIZEN OPPORTUNITIES

QUALITY: Level of scrap, percentage of scrap, direct cost of scrap, quantity of rework, percentage of rework, direct cost of rework, customer returns

COST: Raw material, WIP, finished goods, number of stock turns/year, waste/motion, overtime level

DELIVERY: Customer demand, percentage of on time delivery, lead times, cycle times, TAKT time, layout efficiency, degree of production flow, percentage of lost time, average changeover time, time lost due to breakdown

TRAINING TOPICS
Kaizen Training Needs
Team Building
Team Meetings
Cross-Functional Teams
Self-Directed Work Teams
Cross-Training Activities
Boundaries and Guidelines of Empowerment PDCA-Plan-Do-Check-Act
SDCA-Standardize-Do-Check-Act
Kaizen Tracking Systems
Kaizen Tools
Fundamental Principle Of Kaizen
Anything that does not add value to the product is waste and must be reduced or eliminated!
Major Components Of Waste
Overproducing finished goods
Waiting (people, material, equipment)
Moving material or equipment
Process downtime
Excess inventory (Raw or WIP)
Unnecessary Human Motion
Producing defective goods

KAIZEN PRINCIPLES
Challenge the “way it’s always been done”
No preconceived ideas, open your mind!
Ask “WHY?” 5 times to find root cause
More heads = more good ideas
There are no excuses, only solutions
Experts are people who work in the process
Creativity before capital
Try changes, then adjust
Avoiding analysis paralysis

ELEMENTS OF KAIZEN SUCCESS
Well-developed, clear mandate
Balanced, multi-disciplined team
Clearly defined roles of participation
Team preparation and training
Action plan

KAIZEN BLITZ RULES
Participate full time
Be on time at start of each day and after breaks
Be sensitive to the process owners and entire workforce
Communicate with & include those affected by the changes
Treat others as you would have them treat you
Keep a positive attitude and an open mind to change
Never leave in silent disagreement
Create a blameless environment
One person, one vote, one rank
No such thing as dumb questions
Understand the process, then improve it!

KAIZEN BLITZ ACTION PLAN
Meet first morning for training & brainstorming
Form sub-teams, collect baselines, assign action items
Run trials, modify as needed
Communicate constantly
Standardize new processes
Present results
Benefits Of Kaizen Blitz
Atmosphere of empowerment
Core of trained facilitators who are regarded as change-drivers
Springboard to other teams
Tendency to “Blitz” other challenges
Positive reinforcement

SIX KEY POINTS FOR A SUCCESSFUL KAIZEN BLITZ
1. Driven from the top
2. Stay focused on mandate
3. Team is totally empowered
4. Don’t over analyze
5. Think “outside the box”
6. Maintain high energy!

MAPPING THE VALUE STREAM TO DISCOVER THE OPPORTUNITIES
The information gathered during this phase will help to accomplish the following:
Gather Current Process Data
Define The Scope Of The Process Kaizen Events
Establish Roles, Resources, Boundaries, Measures and Countermeasures
Create Sub-Teams
Identify The Value Stream Connected To Your Product Delivery System
Develop A Blueprint To Apply The Lean Production Principles
Customize and Pack Your Lean Toolbox
Gain Consensus On Customer/Supplier Participations
Determine Training Needs





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