Quick overview on how to conduct a kaizen workshop.

1. Kaizen Workshop

2. Steps………
1. Identify Objectives
2. Identify Facilitator
3. Identify Team members
4. Prepare for workshop
5. Workshop
6. Present Final Recommendations
7. Celebrate Success

3. Identify Objectives
• Kaizen Charter
– Scope
– Measurable Goals
– Timeframe
• Bigger Picture
– Overall value stream

4. Identify Facilitator
• Energetic
• Organized
• Bias for Action

5. Identify Team
• Familiar with the subject /
process
• Open for change /
experiment
• With ability to influence

6. Preparation
• Data
– Collection, verification, analysis
• Meeting Requests
– Invite, notify, confirm
• Resource
– Plan, request, confirm
• Training Material
– Prepare, proof-read, print
• Schedule
– Kick-off, review, approval sessions

7. Workshop
• Introduction
• Over all value stream charter
• Kaizen Charter
• Q&A
• Suggested Agenda
• Roles & Responsibilities
• Review of Data
• Follow DMAIC

8. Define
Day - 1
• Definitions should be done ahead.
Use workshop to review it.
• What is the problem
• What we want to achieve
• What is in/out of scope
• Process steps
• Visual Map – Spaghetti Diagram
• SIPOC & CTQs

9. Measure
Day 1-2
• Measurements should be done
ahead. Use workshop to
review it.
• Current Value Stream Map
• Activity Process Map
• Defect / Error Rates / Types
• Type of variations
• Process capability

10. Analyze
Day 2 – 3
• If possible, some analysis
should be done ahead.
• Why-Why
• Vital Few
• Work-Flow / Visual indicators
• NVA
• Future Value Stream Map

11. Improve
Day 3 – 4
• Design / Layout
• Standardization 5S
• Design Visual workplace /
flows
• Ergonomics
• Mistake-Proofing

12. Control
Day 3 – 5
• Measures / Criteria
• Audits / Monitoring Plan
• Response plan
• Visual Impact / Control Charts
• Lessons & Communication

13. Final Recommendation
• Issues which are being
addressed
• Proposed solutions
• Business / Process benefits
• Resource requirement
• Assigning responsibility
• Follow-up Plan

14. Celebrations