5. Methodology (PDCA)
A five-day team based process for rapid improvement focused on:
▪ Bias For Action
▪ Creativity Before Capital
▪ End Of Week Results
Concentrating on:
▪ Learn By Doing
▪ Overcoming Resistance
▪ Instilling Kaizen Culture
Rapid Change Through Immediate Action!
Kaizen Breakthrough
6. Kaizen Breakthrough
Principles
▪ Clear Objectives – Charter (established before Kaizen).
▪ Team Based Activity – Involve associates and key resources.
▪ Tight Focus on Time (5-Days).
▪ Quick & Simple Improvements (use all 24 hours if necessary).
▪ Immediate Action (new process functioning by end of week).
▪ Document Project Results – “Before” & “After” Kaizen.
9. Kaizen Five-Day Flow
Kaizen Breakthrough
DAY 1
Develop
Charter
Develop Takt
Time
Document
“Before
Kaizen“
Matrix
Process
Diagram
10. Kaizen Five-Day Flow
Kaizen Breakthrough
DAY 2
Run Time
Studies
Capture
Layouts
Spaghetti
Charts
Capacity
Table
Waste Walk
DAY 1
Develop
Charter
Develop Takt
Time
Document
“Before
Kaizen“
Matrix
Process
Diagram
11. Kaizen Five-Day Flow
Kaizen Breakthrough
DAY 2
Run Time
Studies
Capture
Layouts
Spaghetti
Charts
Capacity
Table
Waste Walk
DAY 3
Implement
Changes
Remove
Constraints
Run New
Time Studies
Implement
New Tools
Check Quality
DAY 1
Develop
Charter
Develop Takt
Time
Document
“Before
Kaizen“
Matrix
Process
Diagram
12. Kaizen Five-Day Flow
Kaizen Breakthrough
DAY 4
Run Improved
Process
Document
Any Issues
Verify
Changes Are
Positive
Make Sure
Line Flows
DAY 2
Run Time
Studies
Capture
Layouts
Spaghetti
Charts
Capacity
Table
Waste Walk
DAY 3
Implement
Changes
Remove
Constraints
Run New
Time Studies
Implement
New Tools
Check Quality
DAY 1
Develop
Charter
Develop Takt
Time
Document
“Before
Kaizen“
Matrix
Process
Diagram
13. Kaizen Five-Day Flow
DAY 2
Run Time
Studies
Capture
Layouts
Spaghetti
Charts
Capacity
Table
Waste Walk
DAY 3
Implement
Changes
Remove
Constraints
Run New
Time Studies
Implement
New Tools
Check Quality
DAY 4
Run Improved
Process
Document
Any Issues
Verify
Changes Are
Positive
Make Sure
Line Flows
DAY 5
Kaizen Breakthrough
DAY 1
Develop
Charter
Develop Takt
Time
Document
“Before
Kaizen“
Matrix
Process
Diagram
Develop New
SOP’s
Document
“After Kaizen”
Matrix
Train All
Associates
Broadcast
New Process
Submit Project
paperwork
16. ▪ Kaizen Charter – should be first page of project paperwork.
▪ Wastes Observed – list of waste observed on waste walk.
- Calculate NVA/VA Ratio, Spaghetti Chart, Time Observations, Inventory Counts
▪ Before and After Layouts – show machines, people, product, WIP, etc.
▪ Process Capacity Table – captures manual and machine dependency.
▪ Kaizen Newspaper – list of activities that took place during the Kaizen.
▪ Document Project Results – 'Before' & 'After' Kaizen Matrix
- Pictures, lots of pictures!
Kaizen Report Out
Note – these points are a guideline and not an all inclusive list.