A Course in Kaizen Tools
A class teaches the basic continuous improvement tools associated with the Kaizen process such as Flow Chart, Fishbone Diagram, Histogram, Correlation Diagram, etc. More advanced problem solving tools such as Cross Functional Process Mapping, Why-Why Analysis and FMEA are covered during the second day of training.
Each technique is illustrated using team exercises. The participants measure data, analyze it using charts and learn how to draw conclusions from the data. All exercises are conducted in small groups to promote teamwork and group problem solving. At the end of the course there is a quiz to test acquired knowledge.
Kaizen Blitz Workshop
A Kaizen Blitz process begins by choosing a manufacturing process, work cell or an area where improvements will be implemented. Next, a cross functional team composed of employees from many ranks is selected to participate in the workshop.
Kaizen Blitz itself is 3 to 5 days long, depending on the complexity of the selected production area. The Workshop begins with intensive training that includes team building exercises and overview of Lean Manufacturing tools. Next, the team analyzes the current process and identifies inherent waste, brainstorms improvements, creates an action plan and immediately implements it in the work place. All changes are standardized to ensure they will be maintained. Typical results include increased productivity, improved quality, reduced work in process inventory, improved safety and other key process indicators.
The Kaizen Blitz process ends with a 30 day follow up meeting during which the team reviews implemented changes and suggests future improvements.
What is Kaizen?
Kaizen is a Japanese word that means Continuous Improvement. It describes a management philosophy that embraces small but continuous changes to the workplace as opposed to infrequent large company reorganizations. In the long run, Kaizen brings better results.
Kaizen philosophy requires the participation of all employees in the change process. Kaizen breaks down organizational barriers and above all encourages line employees to have a say on how their work is performed. The most commonly found forms of Kaizen are structured problem solving meetings of workplace teams.
A Kaizen Blitz Workshop is a practical and effective way to introduce a Kaizen culture to a company. During the workshop, which typically lasts from 3 to 5 days, a team analyzes the current process, brainstorms improvements and immediately implements them in the work place. The effects of such action include increased productivity, reduced inventory, improved quality and many other key process indicators.
A3 Report
The A3 Report is a Toyota practice of describing problem definition, analysis, charts and graphs, corrective actions, action plans and other information on a single large page of paper size A3 (A3 is an international term for paper 297 millimeters wide x 420 millimeters long) or 11” X 17” in the US. The A3 report has evolved into a standard method of summarizing a status report, problem solving report outs, quality circles, kaizen project reports, etc.
A3 problem solving refers to a structured problem solving method using the A3 report format as a guide to the team to keep the problem summary on one page of large paper. This method is an off-shute of the A3 report and follows the standard problem solving process of define the problem, contain it, measure and analyze the cause, take corrective action on the root cause, measure results and put standardized controls in place to avoid future reoccurrence.