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Improvement Programs
KAIZEN CONSULTING
Companies
with maturing World Class (Lean) operations programs now have
a powerful tool for taking performance to the
next level. Kaizen means making small, incremental improvements
over an extended period. TCA Kaizen events accelerate the improvement
process by producing dramatic results—often in a week or less.
Kaizen events employ a wide range of improvement tools:
• Setup Reduction
• Cellular Layouts
• Pull Systems (Queue Limiters)
• One Piece Flow
• 5S (Workplace Improvement and Housekeeping)
• Facility Layouts
• Process Improvement
TCA can help jumpstart your Kaizen
program. Our expertise in education, training, and teambuilding
is critical to the success of any performance improvement effort.
We have the technical skills and experience needed to support
Kaizen teams as they pursue meaningful improvements in performance
by upgrading processes, facilities, systems, and people.
Kaizen works when:
• Quick results are needed
• Low cost is a criterion
• A results-oriented approach is important
• Workforce participation is critical
• Major innovations are not expected
Kaizen does not apply when:
• Extensive analysis or engineering is required
• Major innovations are expected
Objectives
Following are the objectives of a Kaizen improvement program:
• Integrate Kaizen improvements into an ongoing Lean strategy
• Ensure that Kaizen is understood and supported throughout
the organization
• Plan Kaizen events that support the organization's visions
and goals
• Achieve significant results from the very beginning of
the Kaizen program
• Reshape the organization's culture by building momentum
behind Kaizen and continuous improvement
The flow chart below presents TCA's general approach to Kaizen
events:
TCA Contributions
• Instruct management team in the Kaizen process
• Facilitate planning for first Kaizen events
• Train Kaizen teams
• Provide coaching and technical support during Kaizen events
• Help measure and document baseline performance and ongoing
performance improvement
• Help Kaizen team present improvement results to the
management team
• Facilitate forward planning and schedule development for
future Kaizen events
Benefits
Kaizen events are results oriented—and should deliver
dramatic performance improvements from the start, such as:
• 98% on-time delivery
• 15+% productivity improvement
• 50% reduction in shop lead time
• 50% reduction in inventory
• 25% reduction in scrap and rework
• Achievement of a World Class look and feel culture
Step-wise approach provides:
• Initial hands-on experience with Kaizen
• Opportunity to create detailed plans for expanded applications
of the Kaizen approach in ways that suit your organization
• Development of in-house resources capable of managing
the future Kaizen process
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