Kaizen Foundations

  • 2 day(s)Duration
  • MDI892Course Code
  • send to printer

Course description

Kaizen is a continuous process improvement philosophy that promotes constant improvement by monitoring business processes and making adjustments. Kaizen involves people at all levels of the organization to participate in Kaizen. This course provides individuals with an awareness of the philosophy and the Kaizen approach and tools. Effectively applying kaizen philosophy and tools can significantly improve value-added productivity and reduce waste and associated costs.

Throughout the training individuals will have the opportunity to apply concepts and techniques in a practical, hands-on, learning-by-doing experience in a simulated environment.

Who should attend

This course is targeted for all employees in the organization that are interested in an understanding of Kaizen and organizational leaders interested in implementing Kaizen in their organization.

What you will learn

  • Gain an understanding of kaizen philosophy and the importance of creating a continuous improvement culture.
  • Describe kaizen goals and guiding principles.
  • Learn a kaizen problem-solving approach and ways to employ it at your organization.
  • Develop a kaizen tool kit.
Course Outline
Module 1: Kaizen Philosophy
  • History of Kaizen
  • The Kaizen Concept and Guiding Principles
  • Kaizen Management (PDCA, SDCA)
Module 2: Kaizen, a Lean Subset
  • Toyota Production System
  • 3M — Muda, Muri, and Mura
  • The 8 Wastes: TIMWOOD Plus
    • Transportation
    • Inventory
    • Motion
    • Waiting
    • Overproduction
    • Over Processing
    • Defects
    • Plus — Non-Utilized Employees
    • Waste Exercise
  • 3-MU Checklist of Kaizen Activities
  • 5W and 1H of Kaizen
  • Exercise: 3-MU, 5W1H
  • 5S Movement
    • Seiri
    • Seiton
    • Seiso
    • Seiketsu
    • Shitsuke
    • 5S Exercise
  • Kaizen Compared to Other Methodologies
    • Exercise: Choosing a Methodology
Module 3: Kaizen Event Overview
  • Ground Rules
  • Leadership Roles
  • SCORE Overview
  • Exercise: Introduction to the Case Study
Module 4: SCORE — Select Step (Week 1)
  • Current State Value Stream Map
  • COPIS (Customers, Outputs, Process, Inputs, Suppliers)
    • Exercise: Applying COPIS
  • Charter the Kaizen Event
      Exercise: Project Charter
    • Exercise: Stakeholder Analysis
Module 5: SCORE — Clarify Step (Week 2)
  • Select the Team
  • Review Current Performance Capability
  • Conduct a Gemba Walk
    • Exercise: Gemba Walk
  • Collect Baseline Data
  • Determine Key Success Metrics
    • Pareto Chart
    • Affinity Diagram
    • Cause and Effect Diagram
    • 5 Whys
    • Exercise: Cause and Effect Diagram (Fishbone)
  • Select Improvement Tools
    • Histograms, Control Charts, Graphs, Scatter Diagrams
    • Exercise: Basic Quality Tool
  • Exercise: Finish Project Charter and Stakeholder Analysis
Module 6: SCORE — Organize Step (Week 3)
  • Prepare the Team Package
  • Train the Team
  • Prepare the Area
  • Ensure Supplies, Materials, and Equipment Are Available
  • Develop and Implement Communication Strategy
  • Exercise: Organize for Kaizen Event Week
Module 7: SCORE — Run Step (Week 4)
  • Day 1: Assess the Current Situation
  • Exercise: Creating the Action Plan
  • Day 2: Make the Changes
  • Day 3: Run the New Process
  • Day 4: Create and Post the New Procedures
    • Visual Management
    • Exercise: Visual Control Board
  • Day 5: The Presentation
    • Exercise: Leadership Presentation
Module 8: SCORE — Evaluate Step (Weeks 5-7) and Implementation Impact
  • Control Plan
  • Kaizen Implementation Impact
  • Exercise: 30-60-90 Day Plan