Week 7 Kaizen Flashcards
DMAIC – Define
Measure, Analyze, Improve, Control – the five phases of Six Sigma
What is a Sensei?
• A Sensei is a teacher who has mastered the skill and possesses leadership attributes
• A sensei is not only a good leader, but a good listener who facilitates kaizen events
What is Kaizen?
• Kaizen is taking apart and making better
- continuous improvement
- It takes project management techniques to facilitate the process and we make the changes.
14 rules for Kaizen
1) open mind
2) positive
3) blameless
4) nonjudgemental thinking
5) Aware of multiple alternatives
6) Respect others as you want to be respected
7) Involve everyone
8) No rank
9) create team
10) no dumb question
11) bias for action
12) creativity before capital
13) no silent disagreement
14) “nuf”
4 phases of team evolution
1) Forming
2) Storming
3) Norming
4) Performing
Kickoff high ranking official input
- Thank people for attending, time and energy for the week.
- Acknowledge support of the team’s decision because it’s focused on observation, data collection and consensus.
- Facilitator has executives cell phone
- Looking forward to report out on Friday
GEMBA
go to gemba means and go to see where the value is.
Waste walk
Sheet of paper with DOWNTIME written down left side of paper. Record as you go examples of each of the 8 wastes.
Kaizen day 1 of 5 - order
Kickoff with exec.
good news check-in
14 rules
record expectations
dive into core lean tools (review tools)
close with check-in
Kaizen day 2 of 5 - order everyday
check-in
review 14 rules and expectations
dive into data collection tools training
go out to the floor
as time allows start implementation
- identify the constraint or issue
- get to the root cause
- brainstorm potential solutions
- select from those solutions
Kaizen day 2 - data collection
It’s very important to be process-focused, but data-driven. Avoid opinions. Expert facilitators for Kaizen events should learn the difference and direct the team accordingly.
- practice in classroom on data collection
- root cause
- data, data, data
- same data collection methods as used elsewhere in the company
Kaizen day 2 - brainstorming
• Don’t let more assertive members dominate the conversation
• You may need to pull ideas from the less assertive team members
• Encourage piggybacking
- Introduce this idea on Day 1
- Piggybacking on others wild ideas is where the great ideas come from
Kaizen day 2 - selecting solutions
simple two-by-two box that says “Ease of Implementation” across the top and “Impact on the Goals” down the left side it says.
Kaizen day 3 - continue two items
Depending on the timing of the activities from Tuesday, participants may actually have started this process on Tuesday and are continuing it into Wednesday� The goal from here on out is to get in as many cycles of brainstorm, select, implement, and measure as possible� The group needs to get as many of those cycles in as they can between Wednesday and toward the end of the day on Thursday�
Kaizen day 3 - 3 more things
- ask the right questions
- 30 day action item list
- Wednesday chaos
Kaizen day 3 - storming
The kaizen event facilitator needs to understand when to let that tension be, because it is helping the creativity. However, when it is actually starting to tear the team down, the facilitator needs to recognize that and have the team take a break.
