Lean Kaizen Working Plan

«  Kaizen Strategy is the single most important concept in Japanese management i.e. the key to Japanese Competitive success.

Kaizen means « On Going » Improvement involving everyone - Top Management, Managers and Workers »

Musaaki Imai  “Kaizen: The Key to Japan's Competitive Success”

In 1986, Imai established the Kaizen Institute to help US companies introduce kaizen concepts, systems and tools.

 

There are 2 approaches to problem solving :

  • The first involves innovation ; applying high cost solutions such as state of the art methodology, Investments…
  • The second uses common sense approach, highly efficient systems, tools and techniques that do not cost money. 

This approach is called KAIZEN. 

 

What is a Kaizen event ?

  • A rapid, learn/do, rigorous and disciplined workshop aimed at creating fast, practical solutions for challenges
  • Involves the people who do the work / own the process through a multi-functional approach, highly focused, action oriented, 3 to 4 days event.
  • Requires a commitment to action, intensive support from Senior Management, a multi functional team which is empowered to make decisions and immediate change
  • Requires a detailed planning
  • Results in dramatic reduction in quality, lead times and costs
  • Energy and momentum to remove waste and make improvements

We can bring improvements to the business by :

  • Investments
  • Borrowing / Developing Technology
  • Engaging consultants

But making improvements with own ideas by all employees on a continuous basis, creates an asset which cannot be purchased.

 

It is an unique lasting culture of an organisation, retained within.

Kiazen atemi consulting consultant lean management
Kaizen

Typical Lean Enterprise results:

Lead Times :

1 / 4 – 1 / 2 Industry Avg.

Inventory Turns :

Greater than 24 / Year

Productivity :

Up to 1 % or more / month

Growth Rates :

3 – 5 times Industry Avg.

 

Value Added time atemi consulting lean management consultant
Value Added time

Value-Adding time (VA) of 3-10% in the Lead Time of products or services is common

Value stream lead time atemi consulting lean management consultant
Value Stream lead time
Value added activities atemi consulting lean management consultant
Value added activities

Value Added versus Non Value Added Activities:

Value Added Activities:

Transforms material & information into products and services the Customer wants.

 

Business Value Added Activities:

Activity that is required to operate the business but the customer is unwilling to pay for.

 

Non Value Added Activities:

Consume resources, but don’t directly contribute to product or service

Lean Working Plan Business Processes atemi consulting lean management consultant
Lean Working Plan Business Processes
Typical Lean Kaizen Methodology and event flow atemi consulting lean management consultant
Typical Lean Kaizen Methodology and event flow
Lean Kaizen roles & reponsibilities atemi consulting lean management consultant
Lean Kaizen roles & reponsibilities

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