Rapid Improvements through a Kaizen Event
WHAT IS A KAIZEN EVENT
Kaizen is a Japanese word which translates to “make change”. A kaizen event comprise of a cross functional team focused on making a permanent change in process performance over a 2 to 5 day period. What make a kaizen event unique is that all improvement activities identified during the event are implemented during the event, not afterwards. This results in the organisation seeing an immediate improvement in a process as opposed to an action list to manage. Metrics impacted by a Kaizen event include increased productivity, cost reduction, reduction in set up time, standardisation of inventory and improved quality objectives. Examples of tools used in the event include operator load charts (Figure 1a) and an output of an event is a standardised work chart (Figure 1b). Such an event requires a commitment by the organisation to release resources completely for the event and to facilitate quick but effective decision making to ensure a successful event.
Figure 1a Standardised Work Chart Figure 1b Operator Load Chart
PROGRAM AIM
The aim of this program is to provide the knowledge and skills to plan, execute and follow up a kaizen event to deliver fast, effective results in a short focused timeframe.
TARGET AUDIENCE
This course is aimed at personnel who are involved in continuous improvement of processes. It is applicable to both personnel leading the change event or key personnel involved in making changes happen.
PRE REQUISITES This course assumes little to no experience of lean or kaizen events.
PROGRAM OBJECTIVES
At the end of this course, you will be able to:
1. Plan a Kaizen Event
2. Execute a Kaizen Event
3. Manage a Kaizen Event team
4. Effectively follow up on a Kaizen event.
PROGRAM SYLLABUS
Session 1 What is a Kaizen event and is it right for you
Session 2 Lean concepts, seven sources of waste and visual factory
Session 3 Planning a Kaizen event – event scope, objectives, team, timing, data collection, training
Session 4 Executing a Kaizen event
Session 5 Team Dynamics and management of a complex team
Session 6 Takt Time and Pitch calculation
Session 7 Spaggetti diagram and inventory chart – purpose, how to complete and analyse one
Session 8 Seven cycle analysis – purpose, how to complete and analyse one
Session 9 Operator load chart & manning levels required - purpose, how to complete and analyse one
Session 10 Capacity chart - purpose, how to complete and analyse one
Session 11 Standard work combination sheet - purpose, how to complete and analyse one
Session 12 Standard work chart - purpose, how to complete and analyse one
Session 13 Single Minute Exchange of Dies (SMED)
Session 14 Metrics – Before and after event
Session 15 Follow up of Kaizen event – action plan, communication, metrics, team acknowledgement
Session 16 Assessment of Learning
ASSESSMENT
On completion of training, trainees will complete a short multiple choice exam.
ABOUT THE TRAINER
The trainer for this course is Maria Ryan, who is a certified Six Sigma Black Belt and Level 6 FETAC certified trainer. Maria has 15 years industrial experience within the Aerospace, Chemical, Medical Device and Pharmaceutical environments. Within these industries, she has worked in varying roles including Design and Manufacturing Engineer, Six Sigma Black Belt, Continuous Improvement Manager, Quality Manager and Process Excellence Leader. On completion of training, trainees are motivated to apply learning on return to the workplace. This is achieved through practical application of tools coupled with Maria’s high energy and passion for superior performance.
INCLUDED IN THE COST
1. Certificate of Attendance and Assessment
2. Venue, Refreshments and Lunch
3. Comprehensive Notes and Reference Material
4. Supply of Kaizen event execution tools and Kaizen event training material
CONTACT DETAILS
Contact Name: Maria Ryan, Training Course Manager
Mobile: +353 87 6226899
e-mail: maria.ryan@crystalbusinesssolutions.ie
Website: www.crystalbusinesssolutions.ie
Registration: Training Registration Form
PROGRAM DURATION 2 days
PROGRAM COST €560.00 per person