Kaizen Best Practices Course
Achieve Massive Results
Use kaizen to continuously improve quality, cost, and delivery (QCD) on a massive scale. Teach associates not only to use lean tools, but to focus their efforts towards measurable and meaningful outcomes.
Align Your Efforts
Promote front-line lean enthusiasm that is smart, scientific, and that affects the bottom line. Tie together the three practices of 5S, waste elimination, and standardization into one holistic continuous improvement model: kaizen!
Create a Continuous Improvement Culture
No more “one step forward, two steps back.” Gain traction with lean that endures for years to come by establishing a culture of continuous improvement
Included in this Course
Deliver Training on Your Terms
Section 1: Introduction
What is Kaizen?
- Discover that kaizen means small changes for the better, not big.
- Learn the phrase, “everyone, everywhere, every day.”
- Find out where 80% of your potential improvement comes from.
Kaizen Improves Standards
- Find out what kaizen improves: standards!
- Learn the two functions of kaizen: to maintain standards and to improve standards.
- Realize that standardization is what sustains the gains of kaizen.
- Understand the difference between physical and non-physical standards.
Quality, Cost, & Delivery (QCD)
- Learn to focus and align kaizen activities towards improved QCD
- Realize that the customer wants the “highest quality at the lowest cost with the best delivery.”
- Understand how all three performance measures are interrelated.
The Kaizen Trinity
- Discover the three practices of the kaizen trinity: 5S, waste elimination, and standardization.
- Learn how the kaizen trinity promotes continuous improvement.
- Review each tool in brief and see examples.
The Scientific Method
- Stop improving haphazardly and learn to improve scientifically.
- Discover the PDCA cycle (plan-do-check-act).
- Realize how PDCA is disciplined and differs from DDDD.
Section 2: The Highest Quality
Focus on the Process
- Realize the difference between quality products and quality processes.
- Learn that high quality processes result in high quality products.
- Learn to end reliance on inspection by building quality in at the source.
- Follow a funny example of making a cup of coffee.
- Learn the definition of a poka yoke.
- Realize that a poka yoke prevents problems from occurring in the first place by eliminating the potential human error.
- See examples of a poka yoke in everyday life.
Don’t Receive, Don’t Make, Don’t Ship
- Discover what it means to “build quality in at the source” by developing in-station quality.
- Learn to achieve quality from three perspectives: incoming, in-station, and outgoing.
- Learn the priority of these three types of quality controls.
- Understand that “the next process is the customer.”
Section 3: The Lowest Cost
Seven Cost Reducing Strategies
- Realize that cutting cost matters and is essential to every organization.
- Understand although there are “bad” ways to cut costs, these are not lean ways!
- Learn the seven cost-cutting strategies to focus waste elimination efforts.
- Realize that improving quality should be your #1 cost-reducing strategy.
- Learn the concept of “cost of poor quality” and the many benefits of quality improvement.
- Follow an example of poor quality in order to realize its financial impact.
- Define productivity in terms of output and input.
- Learn what productivity is not.
- Learn multiple productivity factors.
- Understand how to best use people that are freed up due to productivity improvements.
- Understand the many consequences of inventory to space, inventory management, lead time, quality, and cash.
- Understand how inventory size affects material flow and cash flow.
- Learn to find problems with flow by looking for inventory..
Shorten the Production Line
- Learn how the length of the production line affects QCD
- Understand how transportation, multiple buildings, and the size of your value stream affects QCD.
- Realize how work cell design and layout can allow for flexible manpower.
- Understand how disruption to the production schedule is costly.
- Learn how downtime promotes a mindset of over production.
- Realize how downtime leads to premature capacity expansion.
- Find out where to get downtime data.
- Understand the value of space as a resource.
- Understand the consequences of poor waste utilization in terms of efficiency and cost.
- Learn five tips for reducing space.
Reduce Lead Time
- Learn how lead times affect inventory turnover, waste, and process feedback.
- Discover the many benefits of a short lead time.
- Appreciate a simple method for measuring lead time.
Section 4: The Fastest Delivery
- Realize that delivery matters to satisfy customers, win more business, and increase flexibility.
- Understand the goal of a just in time (JIT) system.
- Understand the role of lead time and production leveling in improving delivery performance.
- Boost awareness for helpful lean tools.
Short Lead Times
- Learn how to define a lead time.
- Understand how short lead times enable a faster response, faster recovery, and flexibility.
- Learn how waste elimination, continuous flow, and batch sizes contribute to improved lead times.
- Understand the value of production leveling in simple terms.
- Learn two keys to effective production leveling: 1) good mixing, and 2) pattern production.
- Witness a simple example of leveled production.
Section 5: The Scientific Method
- Learn the four steps of PDCA: plan, do, check, and act.
- Realize the use of PDCA for both big and small challenges.
- Appreciate the value of small and rapid experimentation.
- Witness a simple example of PDCA in application.
FastCap Case Study
- Witness 16 rounds of rapid PDCA in action while watching the external YouTube video “Kaizen FastCap Style.”
- See how small-scale experimentation can be leveraged to address big or complicated problems.
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