One ofthe most efficient Lean-tools for achieving results in a very short period of time, even a few days, is the Kaizen workshop (Kaizen Event). Kaizen is based on Lean thinking and means continuous improvement in small steps. The Kaizen method has long been used in industry and more recently with increasing success in other sectors. The Kaizen workshop is suitable for situations where you want to improve a process together with your employees and achieve sustainable results. A prerequisite for successful Kaizen is sufficient support from management, 100% employee presence during the Kaizen Event and the cyclical nature of the process to be improved in the short term, so that the process can be monitored as quickly as possible.
Results to be achieved with Kaizen
Typical, often simultaneous, outcomes of kaizen workshops are:
- 30-50% increase in process efficiency,
- a 90% reduction in lead times, and
- 30% improvement in job satisfaction.
Other benefits of Kaizen include: immediate implementation of solutions, management and employee engagement, low time investment, rapid management of resistance and improved employee capacity.
The steps of kaizen
A typical Kaizen consists of three phases:
1. Preparation
- Management support, problem and goal definition, resources, communication, data analysis, logistics, etc.
- This phase usually lasts 1-2 weeks and the team's effort in this phase is about 10% of their time.
2. Kaizen Event
- Analysing the process, identifying the root causes and developing solutions to address them. Below is an example of the steps of a 5-day Kaizen workshop.
- The phase lasts 3-5 days and it is important that the team participates 100% in the Kaizen days.
3. Lean Implementation and Continuous Improvement (15-20 days):
- After the Kaizen Event, the results are implemented immediately and the sustainability of the results is monitored with critical performance indicators. The techniques learned in Kaizen also enable employees to continue to improve their process in small incremental steps.
- This phase takes 15-20 days, with the team contributing around 10-25% of their time.
Lean and Kaizen training
Train to become a Lean and Kaizen change manager. Learn process improvement, Lean facilitation, Kaizen workshops and continuous improvement in an effective and fun 5-day training course.
If you have any questions, please contact us.
Lean Six Sigma,
Certified Lean Six Sigma Master Black Belt
