TheLeanEnterprise20AllAboutKAIZEN(持续改善)

TheLeanEnterpriseAllAboutKaizenLeanFoundationsContinuousImprovementTrainingAnothermethodology:KaizenWithintheContinuousImprovementtoolsarena,perhapsnoneismorecriticalthanKaizenevents.Whileotherleantoolsmaystandalone,KaizensseektochangecultureandprocessesthroughtheutilizationofmanyoftheleanenterpriseprinciplesKaizensseeksmalldailyimprovementsresultinginlargeyearlysavingsComparedtoalarge-scaleDMAICproject,Kaizensfocusonshort-term“blitzes”tomakeimmediateimpactandchange(changeforthebetter)TheprocessofleadingaKaizenhowever,followstheDMAICformatLearningObjectiveThissectionseekstostandardizetheprocessofKaizensinanattempttoprovideusefultoolsallowing‘first-time’facilitatorsto‘hitthegroundrunning’withaprojectoftheirown.Oneimportantconceptistostartsmallandtacklethemorecomplexproblemsatalaterdate-oncemomentumisbuiltandtheKaizenprocesshasbeenunderstoodSomeofthetoolsincludeaKaizenSchedule,KaizenAreaImprovementSheet,7Wand5Sforms,AreaActionForm,PrioritizationMatrix,andaProblemRecordSheet(Theseareembeddedinthepresentationandlocatedinformssection…)OverviewKaizenisoneofthecriticaltoolswithinaContinuousImprovementProcess(CIP)MistakeProofingSet-upReductionTPMStandardizedOperationsProblemSolvingKaizeneventsVSM5SOverviewWhatisKaizen?(Ky-Zen)“ContinualImprovement”Kai=ChangeZen=Good(fortheBetter)TheBasicPhilosophyIstoInvolveAllEmployeesinSmall,DailyImprovementswithintheirWorkAreas.OverviewBenefitsofSmallDailyImprovementscanAddUp20%Improvement(OneTime)20%(OneTime)1/10of1%(EveryDay)1/10x250Workdays25%ImprovementPerYearDMAICandPDCAIdentifyWasteCollectDataIdentifyDesiredResultFindaSolutionStandardize(ROLL-OUTSOLUTION)PreventRecurrenceMistake-proofEvaluateImplementSolution(PILOTfirst)Achievedesiredresult?ActDoPlanCheckDidnotachievedesiredresultFIRST-Standardize,Do,Check,Act(Ensureprocessisstable)THEN–Plan(formoreimprovement),Do,Check,ActDMAICWhatisaKaizenevent?AKaizeneventisaplannedevent(2-5days)ofintenseimprovementactivitiesdirectedatspecificareasofthebusinesstowardalargergoalKaizeneventsareessentiallynarrow-focused,short-termDMAICprojects.ThesecanALSObedoneaspartofanyLean,BBorGBprojectAKaizeneventisacycleofimprovementHowdoIdoaKaizenevent?YoudoaKaizenthesamewayasaDMAICprojectandusingPDCAasyourguideOverviewCycleof‘Continual’ImprovementStabilizeProcessReviseStandardsExposeProblemsEliminateProblemsReviseStandardsASCDAPCDKaizensfollowacontinuingcycleofimprovementS=Studythechange,assureitisstable–then,improveagain!OverviewKaizenconcentratesonimprovingseveralaspectsofthebusiness:–Kaizenconcentratesonimprovingseveralaspectsofthebusiness:SafetyQualitySpeedHow?ValuetoCustomerWaste(Muda)EliminationWorkingtoTaktTimeTPM5S1-pieceFlowPullSystemBenefitsofaKaizenTeamworkEveryoneisabletoparticipateandmakeimprovementsNooneindividual,butateam,maketheimprovementsCommunicationImprovedrelationsbetweenassociatesandmanagementEducationImprovedproblemsolvingThemoreyouteachsomeonetofishthemorethancanfeedthemselvesAwarenessUnderstandingofbroadissuesandobjectivesoftheorganizationasawholeBetterunderstandingofContinuousImprovementandthechallengesinvolvedwithChangeConfidenceStrongerfeelingsofself-worthEmpowermentIncreasedcontroloverthejobandworkenvironmentwhichfostersownershipandcommitmenttothechangeprocessAllemployeesnowfeeltheyhaveavoiceintheprocess!BenefitsofaKaizenPlanningrequiresgoodProjectManagementDefine(Plan)Measure(Do)Analyze(Check)Improve&Control(Act)HowisaKaizenDone?(WithGoodplanning!)GroundworkPeriod:(D-Phase/Plan)TheKaizenGroundworkPeriodDeterminingAreasofImprovementDocumentcurrentstate(performance)KaizenPreliminaryDayPreliminaryDay:(D-Phase/Plan)7WForm6SForm(Embeddedbelow)YourCompanyKaizenDay1Day1:M-Phase/DoKaizenDay1IdentifyandTrackImprovementActionsKaizenDay1PrioritizeActions:(UseProjectPrioritizationMatrix)HighPriorityLowCosttoImplementWorkMethods(Man)LowPriorityHighCosttoImplementMachineMethodsMaterialsKaizenDay1Suggestions:Takepicturesanddocumentthe‘BEFORE’condition(setup)!!Youmayalsolisttheseona‘ProblemRecordSheet’KaizenDay2Day2:AnalyzePhase/CheckTest/Pilot/VerifySolutionsKaizenDay3Day3:Improve&ControlPhase(Act)CompleteFinalReport-outtoManagementandSponsorsKaizenBestPracticesNorankonteam,eachpersongetsonevote(similartobrainstormingtechniques)Becreative,practical,andopenmindedtootherideas(“Thinkoutside-of-the-box”andbreakParadigms)Don’tblameothersandALLquestionsaregoodquestionsAccomplishasmuchasyoucanduringtheKaizenDocumentresultswithpicturesforpresentationtoshowverificationHAVEFUN!!(Thisisthetimetoworkonculturechange!)InformationtoReviewatInitialRoll-OutMeetingOverviewofProcessKeyFactorsforSuccess:CompositionofteamTeammemberbackgroundManagementCommitmentUp-frontagreementandunderstandingEmployeesarethegreatestresource-givethemthetools,training,&supporttodoagreatjobImplementationWorkshopProcessCommunicateProcesstoallPeopleinWorkAreaDefineCurrentSituationIdentifyOtherOpportunitiesfromAreatobeKaizenedPrioritizeIdeasGeneratedImplementNewIdeasDiscussIdeaswithPeopleinWorkAreaDevelopActionPlanf