Kaizen Workshops and Kaizen Events are both an integral part of Lean Management.
They represent the most effective and efficient way to achieve in the shorter timeframe World-Class performances in Quality, On Time Deliveries and Costs.
The achievement of high levels of performances requires, however, to implement some key elements and advanced principles of Lean Management that can be implemented through Kaizen workshops and Kaizen events, such as :
The elements and principles of Lean Management have not all the same complexity and as a consequence, the effort required for implementation is not the same depending of the subject.
For example, implementing key principles of Lean ; Flow, Pull, Takt and Zero Variation , are much more complex, effort and time demanding than implementing some basic Lean elements and tools.
This is the reason why the implementation of Lean is performed, depending on the complexity of the Lean principle, whether through Kaizen workshops or Kaizen events.
Key principles of Lean Management (Flow, Pull, Takt Zero Variation), are typically performed through Kaizen events usually through a 5 days dedicated workshop multifunctional. Less complex elements of Lean Management are performed through Kaizen workshops typically 2 to 3 days through a multifunctional team.
What are the key elements of a Kaizen workshop or a Kaizen event ?
Leadership and Behaviours :
The organisation infrastructure must be assessed and adapted prior to launching a Lean initiative particularly to enable the implementation of the Integration of All, key Lean Management principle (Integrating everyone, working in teams, no blame culture, etc..).
ATEMI Consulting propose to facilitate top and middle management specific Kaizen workshops in order to align the organisational infrastructure; incentives, policies, business systems and processes that must be aligned and coordinated to elicit the behaviour required for successful implementation of Lean principles and practices.
Flow, Pull, Takt, Key Lean Management principles :
Key elements of Lean Management, Flow, Pull and Takt (Just-in-Time) principles can be implemented rapidly through Kaizen events. These principles focus to identify and remove all sources of wastes within the business (anything that consumes resources and produces no value for the customer) to meet customer demand (delivery of products, services, etc...) exactly, on time, quality and quantity.
Typically the ratio between value added activities and non value added activities (wastes) in non-lean companies is no higher than 7% to 10%. Removing these wastes will allow your company to achieve a competitive market advantage by enabling the following benefits :
Flow, Pull and Takt dedicated Kaizen Events :
Zero Variation principles:
The Zero Variation (Built-in-Quality) principle of Lean management which includes Preventive and Curative Quality, capability of processes, etc.. focus on the shift of mindset and culture from measuring the quantity of defects raised for a given period of time (usually a month in a lot of companies) to embedding a high level of quality within the designs and the processes to make sure products (and services, designs, etc...) are produced 'right first time".
With this system in place, the quality standards are much higher and far less volatile, when compared to traditional quality ways of working. Additionally, not having to perfrom rework activities to process the non-quality, leads to a reduction in the Cost of Non Quality (CoNQ) and an increase in the Throughput of the system.
Zero Variation dedicated Kaizen Events :
Problem solving is a key methodology in Lean Management that helps solve the problems permanently and it is built around the disciplines of the PDCA (Plan Do Check Act) cycle.
Problem Soving is designed to go to the true root cause of problems and can be used systematically in all the company processes and in the supply chain.
Problem Solving gives better understanding of problems and then help manages them. Its focus is on the process that results in problems and not the problem itself, this usually only leads to local fixes. It is applied and used multifunctionally and helps communication and promotes common understanding.
Problem Solving dedicated Kaizen Events :
Cost reduction Kaizen Events :
Standardized Operations Kaizen workshops:
What are the standardized operations?
Andon Systems Kaizen workshops:
Appropriate use of the Andon is fundamental in highlighting Abnormalities :
5S and Workplace Organization Kaizen workshops:
5S is a systematic approach to workplace organisation and housekeeping. Encouraging ownership and self discipline to sustain and further develop working practices.
It aims to :
Total Productive Maintenance Kaizen workshops:
Visual Performances Kaizen workshops:
Visual Management is a tool used to visually convey the current status of an area compared to plan.
Visually highlighting an abnormality as it occurs
Benefits of Visual management :