Kaizen Events (or Kaizen Bursts as they are sometimes called) can produce significant benefits in a relatively short period of time. Used as a rapid fix methodology Kaizen uses logical steps to improve processes.

While a Kaizen event can vary in the time that it takes to complete the activity – we’ve developed a 5 day plan for you to adapt to your own needs to your kaizen event up and running.

A word of warning – skipping steps may result in you not achieving the level of improvement your desire! Note : this is established from manufacturing kaizen events – you may want to adapt your event if you’re a service orientated organization.

Kaizen Event – Day 1

• Agree project scope
• Produce current state Value stream map
• Calculate takt time
• Measure cycle time
• Measure and determine optimum staff requirements
• Capture work sequence

Kaizen Event Day 2
• Design an optimum flow/process
• Optimize organization layout
• Establish effective operator sequences
• Agree and define measures and metrics
• Implement layout

Kaizen Event Day 3
• Complete the layout implementation
• Test new area with existing workforce – amend as required
• Implement new layout

Kaizen Event Day 4
• Run Full production against layout
• Implement measures and metrics
• Document new process and standard work

Kaizen Event Day 5
• Align workforce and objectives
• Assess benefits from
o New vs Old Cycle time and takt time
o Other measures as appropriate
• Conduct lessons learnt review with stakeholders (what worked well what didn’t)
• Plan follow up review in 30 days

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