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Kaizen Workshop Guide

This document provides guidance on facilitating a Kaizen workshop to improve an organization's processes. It discusses planning the workshop by selecting a team, date, and securing necessary resources. The typical agenda involves measuring the current situation on day one, developing ideas for improvements on day two, implementing some changes on day three, and completing documentation and follow-up actions on day four. Key steps outlined include brainstorming, designing, testing, and making improvements to the process. The workshop is meant to be hands-on with opportunities to try out changes directly on the production line or in cells. Preparation checklists are also provided to ensure the necessary people, facilities, equipment and supplies are in place for a successful Kaizen event.

Uploaded by

Andi Yanuar
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© © All Rights Reserved
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73 views12 pages

Kaizen Workshop Guide

This document provides guidance on facilitating a Kaizen workshop to improve an organization's processes. It discusses planning the workshop by selecting a team, date, and securing necessary resources. The typical agenda involves measuring the current situation on day one, developing ideas for improvements on day two, implementing some changes on day three, and completing documentation and follow-up actions on day four. Key steps outlined include brainstorming, designing, testing, and making improvements to the process. The workshop is meant to be hands-on with opportunities to try out changes directly on the production line or in cells. Preparation checklists are also provided to ensure the necessary people, facilities, equipment and supplies are in place for a successful Kaizen event.

Uploaded by

Andi Yanuar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Kaizen Facilitators

Organising
g
g and running
g a workshop
p

A Kaizen problem or not?


Identify
Id
tif
and define
the problem
> 2 weeks
or specialist

< day
Just do it !

Kaizen?

Break
down?

Refer

KAIZEN
Just do it !

Facilitating a workshop

Workshop
pp
planning
g
When do you want to run the workshop?
How long will you need?
Decide on the best team
skills & experience relevant to problem

What
Wh t other
th resources will
ill you need
d
see checklist
holidays,
holidays production schedule
schedule, other events?

Get permission
Inform relevant people
what, when, where, who and what do you want them to do?

Facilitating a workshop

Facilitating a workshop

TPM

Whatt K
Wh
Kaizen
i
modules
d l will
ill you need
d review?
i ?
Prepare Kaizen materials see checklist
Ch k b
Check
base/room
/
iis suitable
it bl
Set the agenda
?
Wh are your expected
What
d outcomes?
?

TQM

SMED

team, others, specialists, materials, operators?

Work Flow
W

Confirm resources

Worrkplace Org

Prepare
p
for the workshop
p

Day
y 1 of the workshop
p
Arrive early
Set-up
p
Kaizen box, table, chairs, refreshments,
flipchart, (power leads, projector)...

Greet the team


Introduce
I t d
yourselves
l
Announce the agenda

Facilitating a workshop

A typical workshop agenda


1. Day 1

a.m.
a
m measure the current situation
p.m. ideas & plan for a new situation

2. Day 2

a.m. design new situation


p.m. make some changes

3. Day 3

a.m. make some changes


p.m. record the new situation

4 Day 4
4.

a.m. complete follow-up action plan


Presentation

20-35%
20
35%
Depending on process
and teaching required

40-60%
Depending on what
the team can achieve

15-25%
Depending on process
and what follow-up
actions are required

Dont forget to teach and act and then repeat


Facilitating a workshop

Measure the current situation


Dont assume that any data provided is correct!
see for yourself
Measure
M
what
h t iis relevant
l
t tto your objectives
bj ti
and
d th
the
process
Use a standard format so you can compare results
across different workshops see form
Divide the work amongst your team don
dontt try to do it
all yourself!
Coordinate the effort and support others
Identify the waste in the process

Facilitating a workshop

Develop ideas & plan for a new situation


Collect feedback from the team what have they
measured and observed?
Brainstorm ideas for improvement
Rank the ideas e.g.
e g smilie chart
Allow time for ideas to form e.g. over night

Facilitating a workshop

Design
g the new situation
This will come out of the ideas phase but you need to
see if it will work
Use
U models
d l tto ttestt layout
l
t
Do some more measurements
Try
T your ideas
id
outt on the
th line/in
li /i th
the cellll
Allow time for designs to mature
Be
B prepared
d to scrap them
h
and
d start again!!!
i !!!

Plan

Act

People and
teamwork

Do

Check

Be prepared for the feeling of failure at this step!


Facilitating a workshop

Make some changes


g

PLZ 35 B

PL
LZ 35

PLZ 3
35 C

Make what changes can be


made at the time
Maintenance
M i t
and
d specialists
i li t
may be required
Involve the line/cell operatives
in your plan
Take actions for other work
that has to be completed at a
future time

PLZ 35 D

Make sure that the line/cell


can operate afterwards!!!
Facilitating a workshop

10

Complete
p
the workshop
p

Record the new situation and compare to the old


Calculate the benefits
Complete the future action plan
Prepare a presentation to spread the good news
Invite management and other departments/lines
Deliver the presentation allow/encourage the team to
participate
i i
Tidy the area/room 5S

THANK THE TEAM !


Facilitating a workshop

11

Pre-Kaizen workshop checklist


People
Get approval
Best team available
Inform:Management
The team
Specialists
Spec
a sts
Audience for presentation
Operators & materials to run
Others?
Facilities / other
Base/Room available
Computer & projector (?)
Flipchart & pens
Presentation board/stand
Refreshments

Equipment
Team name tags
Kaizen modules
Kaizen forms
Paper & pens
Post-It notes
Stop watch
atc
Tape measure
Camera
Floor tape
Marker pens
Other

Facilitating a workshop

12

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