Kaizen is a process improvement tool of lean manufacturing and developed by masaki imai in japan. Now a day’s many organization is started implementing kaizen strategy & drive improvement throughout organization. To implement and taking maximum benefits of kaizen methodology, structurally kaizen implementation is very much important. Kaizen event is a basically pre-planned activity and intention to plan event for internal processes. In this article we understood how to plan kaizen event in organization and its implementation steps.
Kaizen event can be categorized into 2 parts as per mention below.
Short Kaizen Event
To achieve short term goal & small-small internal improvements with kaizen event. Short term kaizen event is generally organize for 3 to 5 days.
Long Kaizen Event
The period of long kaizen event is generally 2 weeks to 3 months and it’s also extended as per organization requirements.
Kaizen Event
After the basic understanding of kaizen and its category, now we deep drive for learn kaizen event. Kaizen isn’t a onetime implementation approach its ongoing process improvement tool. Kaizen event is basically pre-planned activity for internal process improvement. It’s a 5-day activity and every day different task will be predefined. Review below attached kick-off planning for kaizen event.
Event kick-off
Before the start of kaizen event kick-off meeting will be plan. Coordinator describe the individual activity of kaizen event. Kick-off meeting is just gathering session for understanding goal & objective for kaizen event.
Now we understand day wise activity kaizen activity as per below mention.
Day-1 activity
Basically day-1 is divided into 4 parts. Review below attached activity planned for 1st day of kaizen event.
Training: – Intention of training is aware each participation for kaizen event. Aware different lean manufacturing tools use during kaizen event such as waste identification, SMED concept, 6 ‘S’ Methodology, poka yoke, line balancing, bottleneck analysis, one-piece flow, work study and many more.
Scope Identification: – Identify scope of the event & define what are area to be covered in kaizen event for process improvement.
Problem Identification: – after the basic training & understanding about the kaizen event, 2nd important step of day-1 is problem identification. In this stage list down different problem or concerns in area or workstation wise. (if possible) next step is select specific & important problem, require to be short out within kaizen event time period.
Team Formation: – Team formation is the last step of day-1. As per selected specific problem developed cross functional team that work together for next 4 days and improve process. During team formation ensure, problem area related concern person must be part of team and also includes different department person for better clarity & take benefits for new ideas and different throat process for process improvement.
Day-2 activity
Second day is divided into 3 activity and overall tough rather than day-1, because on this day kaizen event participants think on problem solution. Review below attached structural steps of day-2.
Data Collection: – Data collection is a very important part in day-2. Understand the problem effectively & collect specific data of problem such as cycle time of operation, process flow chart, utilization, defect rate, utilization and many more parameters as per the problem requirements.
Brainstorming & Idea Generation: – Based on data collection, analyze data & team gather at one place & identify probable solution of problems with the help of brainstorming session. Based on numbers of idea generation select suitable idea for problem.
Idea implementation plan: – After the idea generation prepare a plan to implement changes in operational processes. Identify resources needed & take support with coordinator and prepare plan.
Day-3 activity
Day-3 are spend on only one activity and this day are very toughest in the kaizen event.
Idea implementation: – As per idea implementation plan, implement problem solution to ground level & activities involved for implementation plan such as provide training to operators & those who are working on ground level for improve current process, modify the process with the help of maintenance team.
Day-4 activity
Day-4 are mainly divided into two parts and overall day planning similar as day-2. Review below attached point as per below.
Measure the process with data collection: – measure the process with data collection similar as day-2 and identify process improvements & savings. Identify key performance measurement metrics to monitor and improve process on continuous basis.
Identify gap & variations: – Review process and ensure implement changes as per planned. Identify probable solution & implement changes to fulfil gap for operational processes.
Day-5 activity
Day-5 is the last day of kaizen event and review attached activity below for last day.
Record the kaizen: – now in past 4 days’ team overall identify problem & recommended solution for process improvement, now it’s time to record entire 4-day activity in structural kaizen record sheet in presentation form so everybody taken learning from recorded kaizen.
Celebrate the Success: – Finally this is the last step to celebrate success of kaizen event. In this step recognize efforts for every participation in kaizen events and its help to improve employee’s morale and help to successfully plan future kaizen event.
Important key learnings from kaizen event.
To practices kaizen event on regular basis improve certain skills of employees of organization as per mention below.
- Problem solving skill.
- Improve internal team work.
- Learn how to completion of target within deadlines.
- Understand the gap between on paper thinking & practical implementation.
- Improve presentation & communication skill.
- Improve data collection & Analysis skill.
- Improve decision making skill based on data.