The Kaizen Workshop Online Training Module is designed to help understand how to organize a Kaizen (Continuous Improvement) workshop, in which you will start to implement the plan you made during the value stream mapping activities.
Briefly, Kaizen is a Japanese term, and it means change for the better, aka an improvement.
Kaizen Key Principles:
- Action-based – Don’t analyze to death, just try it.
- Creativity before capital expenditure – Do what you can with what you’ve got – before resorting to spending money.
- Employee involvement – Everybody gets involved, especially the operator.
- Equal application for transactional and manufacturing
Although Kaizen is being applied daily through the interaction between the manager and the employee, using the continuous improvement routines, and also through an employee suggestion system, the topic of this module is the kaizen event, and how to organize a kaizen workshop.
If you are planning to also provide on-site (in-classroom) training for your team, we strongly recommend that, beside taking this module online, you check out our Kaizen Workshop Presentation (PDF format), which we provide separately, for a one-time cost. When used together during the training session, your team can experience the true power of what they’ve learned.
You can start right away on this module, but we strongly recommend you first do the following:
- Move from a functional organization to a value stream organization. Only then, you can see the whole pictures of how each department is aligned, and how they are able to contribute.
- And then, start the training and the application of the continuous improvement routines, and the problem-solving methodology. This way, it will be much easier to develop the strategic plan, of closing the gap towards the vision, step by step, year over year.
- Develop your Lean Policy Deployment (Strategic Plan). Value stream mapping is just a way to visualize and prioritize the activities that will be aligned to the vision of producing enhanced value to the customer in the shortest amount of time with minimum overall cost for the business. If the actions are not incorporated in the overall strategic plan, they will not get supported financially and otherwise, or else, what is the purpose of a policy deployment?!
- Draw the Current State Map using the Value Stream Mapping Methodology. Suddenly, now you have a good picture of the current state of the value stream you need to work on, and how it is linked to various value stream (product families). You also have access to financial and people resources, and everything is aligned to the true North. Without these ingredients, your effort will be local at best, and not sustainable, because it’s not enough to stop here, you will need to write instructions, set the standardized work, and train everybody, and this requires a lot of planning and collaboration.
- Go through Continuous Flow training, Cellular Layout Training, SMED Training, because the Kaizen workshop is simply putting in action the plans you’ve made during those modules.
- Understand how to organize a Kaizen workshop
- Kaizen Basics
- What is Kaizen?
- Why Kaizen?
- Kaizen Thinking
- Kaizen Key Principles
- 10 Rules of Kaizen
- Classification of Improvements
- The Kaizen Workshop
- What is a Kaizen Workshop
- Rules of a Kaizen Workshop
- The Facilitator’s Role
- Team Selection
- Kaizen Workshop Steps
- Plan before the worshop
- Plan during the workshop
- Do – Implement (during the workshop)
- Check (after the workshop)
- Act(after the workshop)
- Planning for the Kaizen Workshop
- The A3
- Define the Problem, and the Challenge
- The Cross-Functional Team
- Preparing the Area
- Data Collection Plan
- Identifying Opportunities (VSM)
- PLAN Phase during the Workshop (Case Study)
- Review data, refine the problem definition and goals
- Understand the current state and identify the potential causes
- Brainstorm countermeasures
- Prioritize countermeasures and plan implementation
- Work through the Case Study
- DO Phase during the Workshop (Case Study)
- Perform experiments to check feasibility before moving equipment
- Move processes/equipment closer together – Example
- Equipment Considerations
- Balance the line
- CHECK, ACT, Reflect
- Check: Measure Success and Benefits
- Act: Review results and standardize / formalize improvements
- Reflections. Where do we go from here?
- The Kaizen Workshop Training (online only)