Wednesday, 14 March 2018

Steps to Running Kaizen Event

Kaizen Event

Kaizen Event or kaizen blitz is an "event" or mini project that is done at a certain time to a certain area (or value stream) that needs improvement, with specific goals and objectives. This Kaizen short project generally lasts for 2 to 5 days, depending on the needs of the company. Because of its "instant" nature, Kaizen Event is often called the " rapid improvement " program.

How to initiate Kaizen initiative correctly?

Indeed there are several steps that must be done for Kaizen Event to run effectively and on target, and resulted in significant improvements. Here are the steps suggested by Lean experts:

  1. Determine the Problem Area:

    At this stage the topic of the problem is determine as the target of Kaizen event. Problems to be addressed can be select by means of value stream mapping (VSM), taken from problems that occur in one area, or it could be a business priority that has not been achieved. The problem should also be described and clearly defined to the entire team, in order for the team to have a common perception. Target should also be in accordance with the needs and goals of the company.

  2. Set Goals and Objectives :

    When initiating Kaizen for the first time, start with a simple goal. Objectives are relatively easy to achieve for example: create a comfortable and conducive working environment by applying 5S, improve flow, or create visual management. Some other simple ideas to target Kaizen can be to create standard locations, create standard tool stations, speed up change-over time, reduce product defects, minimize breakdowns on machines, or create kanban systems. Simple and easy-to-reach goals will improve employee morale and foster optimism in running improvement programs, especially to create the momentum necessary to move up to the level of more complex improvement programs.

  3. Team Shape:

    The team that will run the Kaizen event generally amounts to 6 to 10 people, depending on the needs. Each team should have people from different divisions and sections. So that later ideas and perspectives will be fresher and more varied. Teams that are focus on the Kaizen event should not be bothered by their usual daily routine work, and only focus on the goals specified in the kaizen project.

  4. Provide Kaizen Training

    If the team is doing kaizen for the first time, it is important to conduct a special training on kaizen before starting the project. The training should include the understanding and objectives of the Kaizen event. The targets to be achieve. The steps that must be take to maximize the objectives, how to execute them, and also the training on the tools using in root cause analysis for use in problem solving sessions.

  5. Perform Measurement

    Before beginning any improvement initiative, it is important to have a baseline measurement. Which can be used as a comparison for final measurement after the project is complete. This is useful for assessing and deciding whether the program is effective or not. This data should be ready before Kaizen event begins.

  6. Perform Root Cause Analysis

    Once the issue is obtain, the scope of the problem is clear, the baseline is available, do root cause analysis. To do problem solving. There are some tools that can be use such as Fishbone Diagram, 5 Why Analysis, Affinity Diagram, Fault Tree Diagram, Benefit Effort Matrix, and so on. Then do the validation directly in the field through Gemba.

  7. Implement Corrective Action

    By doing root cause analysis, the root of the problem will be found. If the team has found and understood the root of the problem. It should immediately make a repair plan and take immediate action to fix the root of the problem.

  8. Check ResultsNow corrective action has been taken, and it's time to check the results. There are indicators that indicate whether the team's performance in making improvements has been effective.  Or there are still shortcomings. If there are still shortcomings, re-analyze.

  9. Standardization

    If results have proven effective, then make a standard. This standard will serve as a benchmark for further improvement programs to ensure that the results are sustainable and can be run consistently.

  10. Perform Follow Up

    For some unfinished problems and actions during Kaizen event, follow up  and make sure all actions are done properly. Do a review to ensure the results are sustainable and run consistently.

  11. Perform and Repeat Cycle

    After creating improvement with Kaizen Event with consistent and sustainable results, celebrate the success with the team. In high moral conditions, plan to kaizen the next event. By running the Kaizen Event, both companies and employees will get many benefits. In accordance with Kaizen's objectives, at the company there will be increase performance. Such as increased productivity, increased yield, increased throughput and will certainly support the creation of better quality products. With Kaizen, companies can start reducing inventory, accelerate changeovers, make workplaces more efficient, work more lightly and benefit more.

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