Akaizen event is a cost-effective method for creating dramatic improvements in processes. Kaizen is a Japanese word that means “to make people’s jobs easier by taking them apart, studying them and making improvements.” The intent of a kaizen event is to make people more productive by improving their work environment and streamlining the process. The goal is not a 100-percent solution that solves all the problems at one time, but a 60-percent solution that can be accomplished in a one-week time frame—with the intent to hold another event in several months to further improve the process.

Key concepts of kaizen include:
• If there is no action there can be no success.
• Quick and simple is better than slow and fancy.
• Be creative and get the new process in place and working.
• The process doesn’t have to be perfect the first time.
• No idea is a bad idea.
• Make improvements with what you have (or less) using existing people, machines,
computers and space.
• The best knowledge resides with the people who actually perform the work.

During a kaizen event, the people involved analyze the process, make recommendations on how to improve it and make the physical changes to the process. This approach assures they will also support and continue the process after the event is over. Usually a changeover is analyzed as part of a kaizen event. But a kaizen event also includes application of tools such as total productive maintenance and standardized work.

Kaizen team

A one-week kaizen is intense and busy. Team members should be released from normal day-to-day responsibilities and be available at all times during the day. It is important to include a variety of people on the team, ideally:
• 2 operators
• 1 lead
• 1 maintenance
• 1 downstream operation
• 1 upstream operation
• 1 scheduling and/or material management
• 1 production manager

Depending on the frequency of the set-Ups/changeovers, the team should be prepared to collect and record data anytime within the first 24 hours of the event.

Objectives

To make people more productive and organizations more lean by improving the work environment and streamlining processes.

Training approach
• Classroom training
• Small groups
• Floor work

Benefits
• Improve safety
• Improve quality
• Reduce changeover times
• Reduce unplanned downtime
• Improve on-time delivery to downstream operation
• Reduce floor space required for the process

Tools
• Process flow analysis
• Spaghetti diagrams
• Takt and cycle time
• Set-up reduction/quick changeover
• Pull systems
• Mistake proofing
• Total productive maintenance
• 5-S blitz
• Process mapping
• Process flow analysis

Source: Mid-America Manufacturing Technology Center Phone:  (800) 653-4333
Web: www.mamtc.com