Part of a Training Module Series Part of a Training Module Series Kaizen Orientation Training

Agenda  Teams  What Is Kaizen  Why Use Kaizen  Wastes of Manufacturing  Back to Basics  Rules for the Week  Schedule  Final Presentation

Kaizen Cross-functional team working to drive customer focused, sustainable improvements in a given value stream, within a short, structured period of time to support overall business objectives. A Japanese word meaning gradual and orderly, continuous improvement. Kaizen Event (Kai – Change Zen - Positive)

Why should we change what we are doing? We always want it BETTER, FASTER AND CHEAPER! We need to understand how to fix the waste in our system so we can perform BETTER FASTER AND CHEAPER than our competitors!

What is FASTER? LEAD-TIME is the Time From the Minute the Customer Places an Order Until the Minute They Receive the Finished Product

What is CHEAPER? By identifying and eliminating waste, or NON-VALUE ADDED STEPS in our processes, We also reduce COST; allowing us to win more business.

How to make it BETTER, FASTER, & CHEAPER? By Identifying and Eliminating Waste, or NON-VALUE ADDED Steps in Our Processes

What is a “NON-Value Added” Activity? CountingInspection Reading Repair & Rework Stacking & Un-stacking MeetingTransporting SupervisingCleaning

What is a “Value Added” activity? BendingCuttingDrillingFastening Welding Painting Assembling

8 Wastes of Manufacturing  Overproduction  Waiting  Unnecessary Transport  Over Processing or Incorrect Processing  Excess Inventory  Unnecessary Movement  Defects  Unused Employee Creativity

Back to the Basics Who is the Customer? Current State Map Future State Map Implementation Plan Do It! Evaluate

Kaizen Team Rules  Keep an Open Mind  Maintain Positive Attitude  Always Resolve Team Issues  Create Blameless Environment  Mutual Respect  One Person – One Voice  No Question Is Dumb  Understand The Process  Active Participation  Prepare to Work Long Hours  Dedicate To Kaizen Event  Just Do It!!

Confirm Long-Term Results  Follow Ups to Be Conducted by Kaizen Team Leader and Area Manager  Review Status of Newspaper Items  Review Kaizen Report Card  Review Actual Performance of Area  If Targets Are Met, Standardize Process  If Results Are Uneven or Trends Are Negative, Start PDCA Cycle Again

Standard Work Scavenger Hunt- Practical Exercise Let’s go find some waste! Take 15 Minutes…..