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The Practical, How-to Guide to Succeeding with Kaizen Programs and Events Today manufacturers need kaizen's continuous productivity improvement and waste reduction techniques more than ever. Kaizen and Kaizen Event Implementation provides specific, detailed solutions that have proven successful in real manufacturing environments.Ortiz, author of the best-selling Lessons from a Lean Consultant, covers every element of a successful kaizen program and offers techniques for implementing several key kaizen events. Drawing on his unsurpassed, in-the-trenches experience, he shares powerful insights into changing cultures, gaining management buy-in, training, reporting, follow-up, and much more. Whether you're a plant manager, director, engineer, or quality specialist, this book will help you make kaizen work. Avoid common implementation mistakes Find the right champion and establish an effective steering committee Create timelines, select teams and leaders, and define objectives Use kaizen events to implement 5S, standard work, Kanban, and new line designs Includes a chapter-length case study from a real manufacturing firm
Contents
Preface xiAcknowledgments xvAbout the Author xviiIntroduction xixPart I: Kaizen Basics 1Chapter 1: Kaizen and Kaizen Events 3Kaizen 4Kaizen Events 8Chapter 2: The Company Kaizen Program 17Kaizen Event Steering Committee 18Introducing the Kaizen Champion 24Tracking 25Kaizen Communication 33Chapter 3: The Kaizen Champion 39Why a Kaizen Champion? 40Kaizen Champion Skill Sets 41Choosing the Kaizen Champion 47Cost of a Kaizen Champion 49Kaizen Champion Responsibilities 50Alternatives 53Why a Kaizen Champion? 54Chapter 4: Kaizen Event Scheduling 55Four Weeks Before the Kaizen Event 56Two Weeks Before the Kaizen Event 62One Week Before the Kaizen Event 64Final Thoughts on the Timeline 66Part II: Kaizen Events 67Chapter 5: 5S Kaizen Events 69Four Weeks to Go 70Two Weeks to Go 72One Week to Go 73Let It Begin! 74Maintenance 5S Events 845S Sustaining Tips 87Chapter 6: Standard Work Kaizen Event 91Preplanning 92Day One 98Day Two 102Day Three 106Day Four 106Day Five 110Chapter 7: Case Study: Samson Rope Technologies, Inc. 111January 2007 112Kaizen and Kaizen Event Implementation Training 113The Return Visit 114Lean Assessment and Strategy Sessions 115Samson Rope's Kaizen Program 116Kaizen Event 1, May 7-11, 2007: Cell 5, Cell 8, and Splicing 1175S Continued 120Kaizen Event 2, September 24-28, 2007: Maintenance 120Completing 5S 122Kaizen Event 3, December 3-7, 2007: Coating 1232007 Complete 124Lafayette, LA: Lean Assessment 124Kaizen Event 1, February 20-22, 2008: Large Rope 901 125Kaizen Event 2, April 7-11, 2008: Area G, Area D, Area B 127Samson Rope Progress: Ferndale and Lafayette 128Other Samson Rope Employees to Recognize 129Chapter 8: Conclusion 131Index 133
