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Kaizen and Kaizen Event Implementation

by: Ortiz, Chris A.

Kaizen and Kaizen Event Implementation

by: Ortiz, Chris A.

ISBN 13:
9780131584563
ISBN 10:
0131584561
Edition: 1st
Format: Hardcover
Copyright: 04/15/2009
Publisher: Prentice Hall

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Summary

The Practical, How-to Guide to Succeeding with Kaizen Programs and Events Today manufacturers need kaizenrs"s continuous productivity improvement and waste reduction techniques more than ever.Kaizen and Kaizen Event Implementationprovides specific, detailed solutions that have proven successful in real manufacturing environments. Ortiz, author of the best-sellingLessons 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 yours"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

Preface	p. xi
Acknowledgments	p. xv
About the Author	p. xvii
Introduction	p. xix
Kaizen Basics	p. 1
Kaizen and Kaizen Events	p. 3
Kaizen	p. 4
People of Kaizen	p. 5
Leaders of Kaizen	p. 5
Benefits of Kaizen	p. 7
Kaizen Events	p. 8
Common Mistakes Made in Kaizen Events	p. 9
Metrics	p. 12
The Company Kaizen Program	p. 17
Kaizen Event Steering Committee	p. 18
Plant or General Management	p. 19
Manufacturing Engineering Management	p. 19
Quality Management	p. 20
Operations or Production Management	p. 21
Human Resource Management	p. 21
Maintenance or Facilities Management	p. 22
Purchasing or Materials Management	p. 23
Production Supervisor	p. 23
Operator Representative	p. 24
Introducing the Kaizen Champion	p. 24
Tracking	p. 25
Kaizen Event Selection	p. 26
Date and Length	p. 28
Kaizen Event Team Leader	p. 28
Kaizen Team Members	p. 28
Preplanning and Preplanning Responsibility	p. 29
Pre-event Goals	p. 30
Actual Results	p. 30
Event Budget and Event Spending	p. 30
Action Items, Responsibility, and Status	p. 31
Kaizen Communication	p. 33
Kaizen Communication Boards	p. 34
Kaizen Newsletter	p. 34
Kaizen Suggestion Box	p. 35
The Kaizen Champion	p. 39
Why a Kaizen Champion?	p. 40
Kaizen Champion Skill Sets	p. 41
The Seven Wastes	p. 41
Lean as a Business Model	p. 42
5S and the Visual Workplace	p. 42
Kaizen and Kaizen Events	p. 43
Data Collection	p. 43
Setup Reduction and Quick Changeover	p. 45
Line Design and Work Flow	p. 46
Material Replenishment	p. 46
Project Management	p. 47
Choosing the Kaizen Champion	p. 47
Internal Option	p. 48
External Option	p. 48
Cost of a Kaizen Champion	p. 49
Kaizen Champion Responsibilities	p. 50
Training	p. 50
Kaizen Monthly Meeting	p. 51
Communication Boards	p. 51
Kaizen Newsletter	p. 51
Kaizen Suggestion Box	p. 52
Kaizen Event Tracking Worksheet	p. 52
Team Leadership	p. 52
Action Item Follow-up	p. 52
Monitoring Other Lean Initiatives	p. 53
Alternatives	p. 53
Why a Kaizen Champion?	p. 54
Kaizen Event Scheduling	p. 55
Four Weeks Before the Kaizen Event	p. 56
Select the Process/Department/Work Area	p. 56
Make a Tentative List of Kaizen Team Members	p. 57
Select the Kaizen Event Team Leader	p. 58
Establish Team Goals	p. 59
Estimate Event Spending	p. 59
Order Supplies	p. 60
Update the Kaizen Communication System	p. 61
Schedule Outside Assistance	p. 61
Conduct Waste Analysis of the Area	p. 61
Two Weeks Before the Kaizen Event	p. 62
Finalize the Kaizen Team Members	p. 62
Get an Update on Supplies and Outside Resources	p. 63
Ask Team Members to Walk Through the Chosen Area	p. 63
Pick a Room Where the Team Can Gather	p. 63
Analyze the Collected Data and Start Coming Up with Design Ideas	p. 64
One Week Before the Kaizen Event	p. 64
Gather Current State Information	p. 64
Meet with the Kaizen Team Members	p. 65
Place All Supplies in the Team's Gathering Space	p. 65
Meet with the Plant or General Manager	p. 65
Make Food Preparations	p. 66
Final Thoughts on the Timeline	p. 66
Kaizen Events	p. 67
5S Kaizen Events	p. 69
Four Weeks to Go	p. 70
Select the Area	p. 70
Select the Team Leader	p. 70
Tentatively Select the Team Members	p. 71
Establish Goals	p. 71
Event Spending and Supplies	p. 71
Update the Kaizen Communication System	p. 72
Identify the Kaizen Team Meeting Space	p. 72
Schedule Outside Assistance	p. 72
Two Weeks to Go	p. 72
Finalize Kaizen Team Members	p. 72
Get an Update on Supplies and Outside Resources	p. 72
Ask Team Members to Walk Through the Selected Area	p. 73
One Week to Go	p. 73
Gather Current State Information	p. 73
Meet with the Kaizen Team Members	p. 73
Place All Supplies in the Team's Meeting Room	p. 74
Meet with the Plant or General Manager	p. 74
Let It Begin!	p. 74
Day One: Sort	p. 74
Day Two and Day Three: Set in Order and Scrub	p. 79
Day Four: Standardize	p. 83
Day Five	p. 84
Maintenance 5S Events	p. 84
Day One: Sort	p. 85
Day Two and Day Three: Set in Order and Scrub	p. 86
Day Four: Keep Going	p. 87
Day Five	p. 87
5S Sustaining Tips	p. 87
Create an End-of-Day Cleanup Procedure	p. 88
Conduct a Daily/Shift Walk-through	p. 88
Establish a 5S Audit Sheet	p. 88
Create and Maintain a 5S Tracking Sheet	p. 89
Develop a 5S Incentive Program	p. 90
Standard Work Kaizen Event	p. 91
Preplanning	p. 92
Effective Time	p. 92
Volume Requirements	p. 92
Takt Time	p. 92
Process Analysis	p. 93
Day One	p. 98
Red-Tag Team	p. 99
Review the Line Balancing Information	p. 100
Completing the Red-Tag Event	p. 101
End-of-Day Meeting	p. 102
Day Two	p. 102
Line Design	p. 102
Midday Meeting	p. 103
Scrub/Shine	p. 104
Maintenance and Machine Shop Projects	p. 104
Tool Presentation	p. 104
Shadow Boards	p. 105
Subassemblies	p. 105
Day Three	p. 106
Day Four	p. 106
Creating Workstation and Parts Rack Signs	p. 107
Floor Taping and Designations	p. 108
Determining Subassembly Build Levels	p. 108
Installing Shadow Boards and Tower Lights	p. 109
Day Five	p. 110
Case Study: Samson Rope Technologies, Inc.	p. 111
January 2007	p. 112
Kaizen and Kaizen Event Implementation Training	p. 113
The Return Visit	p. 114
Lean Assessment and Strategy Sessions	p. 115
Samson Rope's Kaizen Program	p. 116
Kaizen Steering Committee	p. 116
Communication	p. 116
Kaizen Event Supply Box	p. 117
Monthly Meeting	p. 117
Kaizen Event 1, May 7-11, 2007: Cell 5, Cell 8, and Splicing	p. 117
5S Continued	p. 120
Kaizen Event 2, September 24-28, 2007: Maintenance	p. 120
Completing 5S	p. 122
Kaizen Event 3, December 3-7, 2007: Coating	p. 123
2007 Complete	p. 124
Lafayette, LA: Lean Assessment	p. 124
Kaizen Event 1, February 20-22, 2008: Large Rope 901	p. 125
Kaizen Event 2, April 7-11, 2008: Area G, Area D, Area B	p. 127
Samson Rope Progress: Ferndale and Lafayette	p. 128
Other Samson Rope Employees to Recognize	p. 129
Conclusion	p. 131
Index	p. 133
Table of Contents provided by Ingram. All Rights Reserved.

Amazon no longer offers textbook rentals. We do!

Kaizen and Kaizen Event Implementation

Kaizen and Kaizen Event Implementation

9780131584563

0131584561

Summary

Author Biography

Table of Contents

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