Course description
Kaizen is a continuous process improvement philosophy that promotes constant improvement by
monitoring business processes and making adjustments. Kaizen involves people at all levels of
the organization to participate in Kaizen. This course provides individuals with an awareness of
the philosophy and the Kaizen approach and tools. Effectively applying Kaizen philosophy and
tools can significantly improve value-added productivity and reduce waste and associated costs.
Throughout the training individuals will have the opportunity to apply concepts and techniques
in a practical, hands-on, learning-by-doing experience in a simulated environment.
Who should attend
This course is targeted for all employees in the organization that are interested in an
understanding of Kaizen and organizational leaders interested in implementing Kaizen in their
organization.
What you will achieve
Gain an understanding of Kaizen philosophy and the importance of creating a continuous
improvement culture.
Describe Kaizen goals and guiding principles.
Learn a Kaizen problem-solving approach and ways to employ it at your organization.
Develop a Kaizen tool kit.
What you will learn
Course Outline
Module 1: Kaizen Philosophy
History of Kaizen
The Kaizen Concept and Guiding Principles
Kaizen versus Other Improvement Methodologies
Kaizen Management (PDCA, SDCA)
Module 2: Kaizen Event
Roles and Responsibilities
Data, Data, Data
SCORE
Select
Clarify
Organize
Run
Evaluate
Module 3: The 8 Wastes: TIMWOOD Plus
1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Overproduction
6. Over-Processing
7. Defects
8. Plus - Non-Utilized Employees
Module 4: 3-MU Checklist of Kaizen Activities
1. Muda
2. Muri
3. Mura
Module 5: 5S Movement
1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke
Module 6: Problem-Solving Tools
Pareto Diagrams
Cause-and-Effect Diagrams
Histograms
Control Charts
Scatter Diagrams
Graphs
Check sheets
Kaizen Implementation Impact
Class Wrap-Up
Description:
The Kaizen Teian or Kaizen methodology promotes the sustainable continuous improvement as a
daily way of life for every member within the organization. It supports the flow, implementation
and recognition of improvement proposals made by all collaborators.
Kaizen is the original concept that has been used by Toyota until today and that has become the
culture in all Toyota sites in Japan and overseas.
It provides a structure to channel the opportunities for improvement detected by any employee
and convert them into realized changes that have a positive impact in the way people perform
and perceive their work.
Kaizen requires a formalized structure within the Organization, where collaborator’s proposals
are evaluated, implemented, reviewed and recognized according to their alignment to the
company’s declared objectives for continuous improvement. The recognition system also helps
motivate collaborators to participate, either individually or through team work, in the proposal
and implementation of their improvement ideas.
Benefits:
The benefits of Kaizen include the participation of all collaborators in improving and
transforming (evolving) the organization in small, every day, incremental steps that do not lose
effectiveness over time.
Some of the elements utilized to support Kaizen are: Visual Management Kaizen Boards, Kaizen
proposal format, Proposal scoring matrix, Kaizen rewards system, Monthly metrics reporting,
etc.
Besides the tangible benefits, Kaizen is regarded as a most effective technique to improve
engagement and culture within a company.
Course Outline:
This workshop is based on a “hear-see-do” approach, so you'll learn the key concepts through
instruction, discussion, simulation, and small-group exercise. The topics covered are:
Kaizen: Toyota’s original concept
How Kaizen fits in the TPS house
Why use Kaizen in your organization
Examples of Kaizen from around the world
How to start a Kaizen culture
What are the steps for preparing the organization
Structural requirements for implementation: training, forms, evaluation, steering board,
guidelines.
Learning Objectives:
At the end of this workshop, you will be able to:
Understand the fundamentals of Kaizen and its importance as a central aspect of a lean system
Document Kaizen improvement
Judge improvement proposals according to their compliance to the Kaizen requisites
Commence a plan for the introduction of Kaizen in your organization
Who Should Attend:
Those who would benefit from this workshop include:
Office personnel and Operators - to understand the importance of following Kaizen as an every-
day occurrence
Leadership- to learn how to evaluate people's Kaizen forms (improvement proposals)
Engineers and lean leaders - to understand how to introduce, support, and teach Kaizen
Organizations at any stage in a lean transformation that are struggling with:
Failures to sustain the results from past suggestions or kaizen events
Problems in getting collaborators to propose improvements for their work areas
Poor ownership and accountability from employees, for changing the status quo.
Kaizen Training Course
Overview
Next available course date:
14th-15th December 2016
A unique two day Kaizen training course which combines the mechanics of a number of
continuous improvement tools with the neccesary change management skills to enable each
delegate to implement sustainable improvement activities within an organisation. Suitable for
Lean Facilitators, Six Sigma Green/Black Belts, Change Managers and Senior Executives within
an manufacturing company.
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£595.00
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Course Overview
Every business strives for continuous improvement in order to satisfy customer demand and
maintain competitiveness. Whilst some initiatives may bring about some instant success,
momentum can soon be lost if the continuous improvement activities are not embedded within
the organisation and its culture. This course shows you one method of bringing about permanent
productive change witihin your business.
What is Kaizen?
One way in which permanent improvements can be brought about is by the use of small
empowered group activities. These improvement activities are often referred to in a lean
environment as Kaizens. Kaizen, originally a Buddhist word, loosely translates to describing all
of the continuous improvement (CI) activities with an organisation.
Kaizen makes uses of small groups of people to make relatively small, positive changes within
their own area of expertise. At Aster, we refer to this as "doing 1000 things 1% better".
This two day Kaizen training course focuses on both the mechanics of generating continuous
improvement activities together with a proven management approach to ensure the right culture
is created to bring about sustainable improvement.
Ideally suited to lean managers, continuous improvement facilitators, company executives, Six
Sigma green/black belts and change managers.
What you will learn
At the conclusion of the course each delegate will be able to appreciate:-
Where waste (non-value added activities) can be found in a business
How to identify prioritised areas for improvement
The kaizen approach to incremental improvement
The soft managerial skills required by managers to both implement and sustain a continuous
improvement culture
How to get difficult people on board the programme
Improvement metrics
Course Content
The Kaizen Training Course covers the following topics:-
Introduction
Kaizen and Kaikaku (Kaizen Blitz) - Definitions
Understanding the origins of Kaizen
7 Wastes – the non value added activities in our organisation
Examples of lean tools to be used for kaizen events
5S, Kanban, SMED, TPM, Value Stream Mapping, Zero Quality Control
Basic Problem Solving – Ishikawa and 5 Whys
How to implement Kaizen?
How to structure a kaizen team?
Company Structure
Winning ‘Hearts & Minds’
Sunrise & Sunset Meetings
MBWA – The Gemba Walk
The Task Board
The CI Office
Project Awareness & Reporting
Summary & Review
Courses are limited to a maximum of twelve delegates. The Kaizen training course cost covers
the training session, a comprehensive set of course notes, lunch and refreshments.
This is a non-residential training course. This course can be delivered in-house if required. For
further information contact Aster Training on 01296 720281 for a Free Consultation to discuss
your training requirements.
Costs are exclusive of VAT which is chargeable at the current rate. Prices are correct at the time
of publishing, but may be varied in line with market conditions from time to time.
