Is a work philosophy that aims to support the implementation of a Continuous Improvement program in business, with the involvement and active participation of all staff; in all levels of the organization.
Kaizen is a daily process, the purpose of which goes beyond simple productivity improvement. It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work, and teaches people how to perform experiments on their work using the scientific method and how to learn to spot and eliminate waste in business processes. In all, the process suggests a humanized approach to workers and to increasing productivity: “The idea is to nurture the company’s human resources as much as it is to praise and encourage participation in kaizen activities.”
A Kaizen Event haves 3 phases:
- Planning and preparation
a. Select a process or activity to improve
b. Define the problem
c. setting boundaries and collecting data before the event
d. Create a work team
e. Prepare the target area
f. Schedule the event.
- Implementation (Kaizen event)
a. Training the participants (1st day) Lean tools, methodology
Kaizen, data review and management of standard operations.
b. Mapping and Analysis Process (2nd day), data analysis and indicators, identify waste and creating proposals for improvements.
c. Walking the gemba-situ process (3rd day), begin pilots.
d. Check the pilot results (4th day), adjust process, document standard practices and release the solution to production.
e. Present results (5th day), review results with the leaders and celebrate the improvement.
- Communication and follow up
a. Post the Kaizen event to the company.
b. Review and monitor the results.
c. Get feedback on the experience from the operators involved in the Kaizen event.
d. Document the results and lessons learned
e. Develop the next event involving new resources.
Here is a short video with a simple explanation about a Kaizen Event.