Kaizen and kaizen event implementation

✍ Scribed by Ortiz, Chris A

• Publisher: Prentice Hall
• Year: 2009
• Tongue: English
• Leaves: 166
• Category: Library

✦ Synopsis

The Practical, How-to Guide to Succeeding with Kaizen Programs and Events

Today manufacturers need kaizen'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 you'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

✦ Table of Contents

Cover......Page 1
Contents......Page 6
Preface......Page 12
Acknowledgments......Page 16
About the Author......Page 18
Introduction......Page 20
Part I: Kaizen Basics......Page 28
1 Kaizen and Kaizen Events......Page 30
Kaizen......Page 31
Kaizen Events......Page 35
2 The Company Kaizen Program......Page 44
Kaizen Event Steering Committee......Page 45
Introducing the Kaizen Champion......Page 51
Tracking......Page 52
Kaizen Communication......Page 60
3 The Kaizen Champion......Page 66
Why a Kaizen Champion?......Page 67
Kaizen Champion Skill Sets......Page 68
Choosing the Kaizen Champion......Page 74
Cost of a Kaizen Champion......Page 76
Kaizen Champion Responsibilities......Page 77
Alternatives......Page 80
Why a Kaizen Champion?......Page 81
4 Kaizen Event Scheduling......Page 82
Four Weeks Before the Kaizen Event......Page 83
Two Weeks Before the Kaizen Event......Page 89
One Week Before the Kaizen Event......Page 91
Final Thoughts on the Timeline......Page 93
Part II: Kaizen Events......Page 94
5 5S Kaizen Events......Page 96
Four Weeks to Go......Page 97
Two Weeks to Go......Page 99
One Week to Go......Page 100
Let It Begin!......Page 101
Maintenance 5S Events......Page 111
5S Sustaining Tips......Page 114
6 Standard Work Kaizen Event......Page 118
Preplanning......Page 119
Day One......Page 125
Day Two......Page 129
Day Four......Page 133
Day Five......Page 137
7 Case Study: Samson Rope Technologies, Inc.......Page 138
January 2007......Page 139
Kaizen and Kaizen Event Implementation Training......Page 140
The Return Visit......Page 141
Lean Assessment and Strategy Sessions......Page 142
Samson Rope’s Kaizen Program......Page 143
Kaizen Event 1, May 7–11, 2007: Cell 5, Cell 8, and Splicing......Page 144
Kaizen Event 2, September 24–28, 2007: Maintenance......Page 147
Completing 5S......Page 149
Kaizen Event 3, December 3–7, 2007: Coating......Page 150
Lafayette, LA: Lean Assessment......Page 151
Kaizen Event 1, February 20–22, 2008: Large Rope 901......Page 152
Kaizen Event 2, April 7–11, 2008: Area G, Area D, Area B......Page 154
Samson Rope Progress: Ferndale and Lafayette......Page 155
Other Samson Rope Employees to Recognize......Page 156
8 Conclusion......Page 158
C......Page 160
F......Page 161
M......Page 162
R......Page 163
S......Page 164
T......Page 165
Y......Page 166