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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 mistakesFind the right champion and establish an effective steering committeeCreate timelines, select teams and leaders, and define objectivesUse kaizen events to implement 5S, standard work, Kanban, and new line designsIncludes a chapter-length case study from a real manufacturing firm
Contents
Preface xiAcknowledgments xvAbout the Author xviiIntroduction xix Part I: Kaizen Basics 1 Chapter 1: Kaizen and Kaizen Events 3 Kaizen 4 Kaizen Events 8 Chapter 2: The Company Kaizen Program 17 Kaizen Event Steering Committee 18 Introducing the Kaizen Champion 24 Tracking 25 Kaizen Communication 33 Chapter 3: The Kaizen Champion 39 Why a Kaizen Champion? 40 Kaizen Champion Skill Sets 41 Choosing the Kaizen Champion 47 Cost of a Kaizen Champion 49 Kaizen Champion Responsibilities 50 Alternatives 53 Why a Kaizen Champion? 54 Chapter 4: Kaizen Event Scheduling 55 Four Weeks Before the Kaizen Event 56 Two Weeks Before the Kaizen Event 62 One Week Before the Kaizen Event 64 Final Thoughts on the Timeline 66 Part II: Kaizen Events 67 Chapter 5: 5S Kaizen Events 69 Four Weeks to Go 70 Two Weeks to Go 72 One Week to Go 73 Let It Begin! 74 Maintenance 5S Events 84 5S Sustaining Tips 87 Chapter 6: Standard Work Kaizen Event 91 Preplanning 92 Day One 98 Day Two 102 Day Three 106 Day Four 106 Day Five 110 Chapter 7: Case Study: Samson Rope Technologies, Inc. 111 January 2007 112 Kaizen and Kaizen Event Implementation Training 113 The Return Visit 114 Lean Assessment and Strategy Sessions 115 Samson Rope's Kaizen Program 116 Kaizen Event 1, May 7-11, 2007: Cell 5, Cell 8, and Splicing 117 5S Continued 120 Kaizen Event 2, September 24-28, 2007: Maintenance 120 Completing 5S 122 Kaizen Event 3, December 3-7, 2007: Coating 123 2007 Complete 124 Lafayette, LA: Lean Assessment 124 Kaizen Event 1, February 20-22, 2008: Large Rope 901 125 Kaizen Event 2, April 7-11, 2008: Area G, Area D, Area B 127 Samson Rope Progress: Ferndale and Lafayette 128 Other Samson Rope Employees to Recognize 129 Chapter 8: Conclusion 131 Index 133
