How To Conduct A Kaizen Blitz
How to Conduct a
Kaizen Blitz
Darcy Priest – Veris Production Manager
Jan 5th, 2005
What is a Kaizen Blitz?
A Kaizen Blitz aims to quickly analyze and implement lean principles on a cellular or subcellular level.
Conducting Kaizen Blitzes in all areas of a production line is the basis of lean implementation.
“Kaizen” is Japanese for continuous improvement, which means lean implementation is a continuous process! Name of the presentation (Edit in Foo
2
What is involved?
A Kaizen Blitz consists of the same key components as lean implementation:
Standard hour and cycle time analysis
Value stream mapping
Root cause analysis
Process and flow analysis
Kanban implementation
Single piece flow
Layout analysis
5S implementation
Name of the presentation (Edit in Foo
3
The Kaizen Blitz Process
Every Blitz is unique, but the key steps are:
Build a team that is focused and trained in the key lean elements
4-8 people max trained in 5S, cycle time and process analysis
Define the scope and set a clear purpose
Determine any key outcomes or constraints
Set the objectives
Be SMART – Specific, Measurable, Achievable, Relevant, Timely
Analyze existing process and cycle time
Think value add, map the process steps, chart cycle time, material flow
Name of the presentation (Edit in Foo
4
The Kaizen Blitz Process
With the original objectives in mind, optimize the following:
Cycle time
Material flow
Inventory/WIP
Cell layout
5S
Visual workplace
Implement the changes
Measure gains from short term changes against original objective
Remember the change process: Where are we?
Where do we want to go? How do we get there?
Name of the presentation (Edit in Foo
5
Build the Blitz Team
The size and skill level of the team can greatly impact their effectiveness If the scope has been properly set, no more than 8 people are required in the core team
An even representation of team lead, engineering, support, and production people must be maintained to ensure
Kaizen Blitz
Darcy Priest – Veris Production Manager
Jan 5th, 2005
What is a Kaizen Blitz?
A Kaizen Blitz aims to quickly analyze and implement lean principles on a cellular or subcellular level.
Conducting Kaizen Blitzes in all areas of a production line is the basis of lean implementation.
“Kaizen” is Japanese for continuous improvement, which means lean implementation is a continuous process! Name of the presentation (Edit in Foo
2
What is involved?
A Kaizen Blitz consists of the same key components as lean implementation:
Standard hour and cycle time analysis
Value stream mapping
Root cause analysis
Process and flow analysis
Kanban implementation
Single piece flow
Layout analysis
5S implementation
Name of the presentation (Edit in Foo
3
The Kaizen Blitz Process
Every Blitz is unique, but the key steps are:
Build a team that is focused and trained in the key lean elements
4-8 people max trained in 5S, cycle time and process analysis
Define the scope and set a clear purpose
Determine any key outcomes or constraints
Set the objectives
Be SMART – Specific, Measurable, Achievable, Relevant, Timely
Analyze existing process and cycle time
Think value add, map the process steps, chart cycle time, material flow
Name of the presentation (Edit in Foo
4
The Kaizen Blitz Process
With the original objectives in mind, optimize the following:
Cycle time
Material flow
Inventory/WIP
Cell layout
5S
Visual workplace
Implement the changes
Measure gains from short term changes against original objective
Remember the change process: Where are we?
Where do we want to go? How do we get there?
Name of the presentation (Edit in Foo
5
Build the Blitz Team
The size and skill level of the team can greatly impact their effectiveness If the scope has been properly set, no more than 8 people are required in the core team
An even representation of team lead, engineering, support, and production people must be maintained to ensure