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Kaizen Event - Typical Results

Why do Kaizen?

The Kaizen method is quite simply the fastest, most field-proven way to:

Shine an intense burst of improvement on a process
Truly involve everyone that has a stake in the process
Hold process stakeholders accountable for measurable improvements
Improve both profitability and employee morale at the same time
Do it again and again; each time squeezing more juice, more value, and happier people

Dollars & Sense

How might your career be affected if you stumble over several common gotcha mistakes when you lead your next big Kaizen Event? (with the Big Wigs flying in from out of town)

How might your career be affected when you lead a flawless Kaizen Event worthy of a case study?

What is a Kaizen Event?

An intensive burst of business process improvement, usually involving...

1) Preparation by the Kaizen Event Leaders

2) Anywhere from a half day to a 5-day "Kaizen Event" - where representatives from every group of stakeholders devote undivided attention to improving one business process with clearly defined boundaries.

Examples of clearly-defined improvement objectives might include:

Reduce costs by 20%
Reduce process cycle time by 50%
Reduce scrap by 80%

(Little 5% improvements are usually not worth the attention of a kaizen event. You are looking for BIG improvements!)

3) The day after the Lean Kaizen Event...

The new process is expected to be actually used!
There are usually a few loose ends to clean up in the few days following the event

The Systems2win templates support the Kaizen philosophy and Lean Manufacturing tools and concepts taught in Creating Continuous Flow
by Rother and Harris

Features & Benefits

All Word & Excel -
Your people already own and know
Professional deliverables - easily stored & shared
Fill-in-the-blanks easy with online help always just a click away

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Kaizen

Kaizen tools, templates, and training
(Sometimes misspelled as "kaisen", "kaisan", or "kaizan")

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Word & Excel templates - Kaizen tools
Lean Kaizen Training Presentation Editable PowerPoint that you can quickly personalize to provide (only) the Lean Kaizen concepts that are needed for your next Kaizen Event Get a free preview of this 130+ PowerPoint Kaizen Lean Training when you sign up for our newsletter
Kaizen Event Planning Checklist Event planning to thoroughly prepare to get the best results from your team's intensive time spent together. When the "big wigs" are coming in from out of town to participate in your next Kaizen Event - you are going to REALLY appreciated having a thorough checklist containing all of the learning lessons of hundreds of other kaizen event leaders. The Kaizen Event Checklist will help you avoid thoughtless oversights that have tarnished the careers of so many of your predecessors.	Kaizen Event Checklist 5 min video
Kaizen Mandate For top management to provide clear direction to the Kaizen Team - in a format that is easily copied to PowerPoin
Agenda More detailed Kaizen planning template. Who will do what, where, and when. And who needs to do what preparation and homework? And when?
Team Roles Maybe YOU know every detail of every Kaizen Team Role, but does everyone else know what they're supposed to be doing? Clear responsibilities for every role needed for a successful Kaizen: Facilitator, Coordinator, Co-Leader, Value Stream Manager, Process Owner, Process Experts, Process Outsiders, Continuous Improvement Leadership Team, Executive Team, and Change Agent. (6 pages)	Team Roles Kaizen template
Ground Rules for Working Together Covenants for mutual respect and productive work habits. How many teams have you been part of that could have benefited enormously from taking a few moments to lay some ground rules - BEFORE someone became a problem?
Empowerment Boundaries Top management's clear communication of what a Team can and must do. Clearly communicated in writing and framed on a wall - so that people don't have to constantly interrupt high level managers to clarify what their team is and is not empowered to do.
Presentation of Results Editable PowerPoint for presenting Kaizen Results to senior management, and then serving as a permanent record of what was accomplished
Action List To collect Issues & Ideas that arise before, during, and in the days immediately following a Kaizen Event, and to assign responsibilities and deadlines to finish up all loose ends in the days immediately following a Kaizen Event
Audit To ensure the sustainability of process improvements
Event Evaluation Form After each Continuous Improvement Event, it is customary for every participant to provide valuable insights
Lessons Learned And what do you do with all of those insights gathered from the Event Evaluation forms? A savvy Lean company organizes them into a Lessons Learned repository. "To improve the ways that we improve"
Potential Future Improvements When people come up with ideas - you don't want to lose those ideas for lack of a means of collecting and organizing them. Kaizen event planning: What might we do next?
Priorities Worksheet "The Leader is the one that climbs the tallest tree, surveys the entire situation, and yells, 'wrong jungle'!" (Stephen Covey - 7 Habits of Highly Successful People) The Priorities Consensus Worksheet provides a proven way for your leadership team to make sure that you choose the processes that are most worth improving.
Schedule Schedule of upcoming improvement events. Once your leaders have agreed upon what do do next, you need a simple way to communicate those decisions.
Also see the many Lean tools that can come bundled with these kaizen tools

Kaizen Training & Demo Videos

Kaizen training
- Kaizen video (9 mins)
- Kaizen Event Checklist (5 min video)
Additional training relevant to these templates
The Sample and Help worksheets of every template also contain training relevant to THAT template
- Introduction to Systems2win templates (5 min video)
- Training & Demos home page

Huge Bonus: Lean Kaizen Training PowerPoint

When sign up for our newsletter -
you get a free preview of this 100+ page Kaizen PowerPoint.

When you purchase the Kaizen bundle of templates -
you get an editable version of this Kaizen ppt, which you can use as the starting point for your own in-house Lean training, to present many of the most common Lean and Kaizen teachings, including:

The essence of Lean teachings
Definitions of takt time, cycle time, value add time, lead time, out of cycle work, and all of the "times" that are so central to eliminating waste as part of Lean process improvement
Criteria for selecting your first Kaizen Event
The transition from top-down to bottom up continuous improvement
5S workplace organization
Differences between Kaizen and Business Process Reengineering
(and which tools to use under what circumstances)
How to organize for "flow"
Types of production environments that embrace flow (and those that don't)
How to standardize work
Batch size reduction
Why flow requires (and produces) higher quality than batch & queue
How to flow around monuments (a monument is any machine or process that doesn't easily handle small batches
How and when to introduce pull systems (to make only what the customer orders)
Tips for how to come close to a level production schedule - even if customer demand isn't level

All of this powerful online training is instantly available and free for every licensed user of your kaizen software - providing "the rest" of what your people need to get the most value from their already-easy-to-use fill-in-the-blanks Word and Excel templates.

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