Kaizen manager

1st Day

LEAN MANAGEMENT PHILOSOPHY

Lean Management and TPS history
Lean versus traditional management system, Lean Office
Value-added approach
Lean principles (5 principles)

LEAN MANAGEMENT CONSTRUCTION ELEMENTS

Pull system, JIT
JIDOKA, 0 defect concept
KAIZEN
Involving employees
Stable Operation

KAIZEN PHILOSOPHY AND APPROACH

Connection of KAIZEN and Lean
Features of KAIZEN 
4 principles of KAIZEN
Examples of KAIZEN implementation
Simulation game - Lean production versus traditional production

2nd Day

GEMBA KAIZEN

5 GEN, Gemba Kaizen approach
PDCA – SDCA cycle
Maintenance and  continuous improvement
Based on facts leadership
Measurement, data collection
Determine targets and requirements

STANDARDS

Function of standards
Steps of standardization
Elements of standardized work
5S METHOD
5S steps, introduction

VISUAL MANAGEMENT

Information structures, control
Examples of visual management 
Involving employees
Employee in the focus principle
Catapult game – PDCA

3rd Day

KAIZEN – Problem solving

Problem solving in 7 steps, Kaizen steps

PROBLEM EXPLORATION’S TOOLS

Defining problem (Tregoe)
Identify KAIZEN possibilities
PQCDSM check list
4M method
5W 1H method
3 MU method
5 WHY method
Task: KAIZEN practice

FURTHER ANALYSIS TOOLS:

Flow charts, Value Stream Mapping 
Performance measurement, Benchmarking
5W 1H method
Spaghetti chart, cycle time chart
Standard work combination sheet
7 MUDA - loss reduction

4th Day

PROBLEM SOLVING

Tools of problem solving
7 QC tools
Before KAIZEN, after KAIZEN
KAIZEN diary, action plan

PROBLEM SOLVING IN TEAM

Brain storming, Affinity diagram
Check list in 7 steps
LOSS REDUCTION
Cycle time balancing
TPM, SMED
Material flow optimization

0 DEFECT CONCEPT

FMEA, ‘good at first’ quality
JIDOKA, POKA-YOKE
KAIZEN STORY BOARD
- Presentation of the KAIZEN results

5th Day

KAIZEN system

Kaizen actions, Kaizen sheets
Kaizen organization, Kaizen levels
Role and duties of the KAIZEN manager
Involving people into KAIZEN activity, motivation

SUGGESTION SYSTEM

Evaluating KAIZEN ideas
Quality circles (QCC)
Cost-benefit analysis

KAIZEN WORKSHOPS LEADERSHIP

Effective teamwork, meetings

KAIZEN IN PRODUCT DEVELOPMENT

QFD, quality planning

KAIZEN IN THE OFFICE

Lean Office, loss reducing in administrative area
Office 5S, process improvement
Pilot project – KAIZEN activity implemented at the participant’s workplace

6th Day

The introduction of KAIZEN, strenghtening in the company

LEAN IMPLEMENTATION STEPS
Change and project management of Lean implementation
Basic conditions of Lean management and Kaizen implementation
Critical success factors of the implementation
LEAN IMPLEMENTATION PROGRAM
Compilation of Kaizen action program

EXAM: Presentation of the individual KAIZEN action, and Written exam