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Lean Office - KaizenLean Office - Kaizen

http://http://www.managementsupport.comwww.managementsupport.com

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OutlineOutline

What is Kaizen?What is Kaizen? HistoryHistory How to KaizenHow to Kaizen The Kaizen BlitzThe Kaizen Blitz RoadblocksRoadblocks

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What is Kaizen?What is Kaizen?

Kaizen (Ky’zen)Kaizen (Ky’zen) ““Kai” means “change”Kai” means “change” ““zen” means “good (for the better)”zen” means “good (for the better)” Gradual, orderly, and continuous improvementGradual, orderly, and continuous improvement Ongoing improvement involving everyoneOngoing improvement involving everyone

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Eight Service Industry WastesEight Service Industry Wastes

1.1. Errors in documentsErrors in documents

2.2. Transport of documentsTransport of documents

3.3. Doing unnecessary work not requestedDoing unnecessary work not requested

4.4. Waiting for the next process stepWaiting for the next process step

5.5. Process of getting approvalsProcess of getting approvals

6.6. Unnecessary motionsUnnecessary motions

7.7. Backlog in work queuesBacklog in work queues

8.8. Underutilized employeesUnderutilized employees

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Identify the Current StateIdentify the Current State

Crucial first step in process improvementCrucial first step in process improvement Deep understanding of the existing processes and Deep understanding of the existing processes and

dependenciesdependencies Identify all the activities currently involved in developing a Identify all the activities currently involved in developing a

new productnew product Observe the process first handObserve the process first hand Identify Value Added (VA), Non-Value Added Required (NVA-Identify Value Added (VA), Non-Value Added Required (NVA-

R), and Non-Value Added (NVA)R), and Non-Value Added (NVA) Generally creates more questions than answersGenerally creates more questions than answers

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Brainstorm and AnalyzeBrainstorm and Analyze

Kaizen team brainstorming to develop new processKaizen team brainstorming to develop new process Post improvement ideas on map or by categoryPost improvement ideas on map or by category

WorkflowWorkflow TechnologyTechnology People / OrganizationPeople / Organization ProceduresProcedures

Develop detailed future state mapDevelop detailed future state map New workflowNew workflow Value Add and Non-Value AddValue Add and Non-Value Add Cycle timesCycle times Identify Kaizen “bursts” (immediate radical change)Identify Kaizen “bursts” (immediate radical change)

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Kaizen BlitzKaizen Blitz

Total focus on a defined process to create radical Total focus on a defined process to create radical improvement in a short period of timeimprovement in a short period of time

Dramatic improvements in productivity, quality, delivery, Dramatic improvements in productivity, quality, delivery, lead-time, set-up time, space utilization, work in process, lead-time, set-up time, space utilization, work in process, workplace organizationworkplace organization

Typically five days (one week) longTypically five days (one week) long