Kaizen Training

6 Step Approach

KAIZEN IS A STRUCTURED AND PROVEN PROBLEM SOLVING APPROACH

WORKING EVERYWHERE
1a. PROBLEM DEFINITION

1b. QUANTIFICATION OF PROBLEM

Problem title:

Problem title:

Owner:

Owner:

Team:

Team:

Conclusion from
quantification analysis: Solving issue 1 would address X% of non-productive time
Description of
problem to solve:

Current outcome:

Target outcome:

What is excluded
from the solution
space:
Nonproductive
time

Issue 1

Issue 2

Issue 3

Issue 4

Issue 5

e ep
problem
ob e a
and
d object
objectives
es
1 Define
2 Analyze the facts

6 Check and make

sustainable

5. PROGRESS UPDATE
Problem title:
Owner:

Status

2b. RANKING OF CAUSES

Problem title:

Period:

Action

2a. ROOT CAUSE ANALYSIS THE FISHBONE

Problem title:
Owner:

Team:

Main highlights since

last review

5 Implement

Main challenges

Solution A2:
Action
A ti A2
A2.1:
1
Action A2.2:

Team:

Man

Owner:

M M

Team:

Conclusion from
Addressing causes A, B, C would solve X% of the issue
ranking:

Machine

Environment

% of inefficiency
caused

Solution B1:
Action B1.1:
Action B1.2:

M M

2003
4. IMPLEMENTATION PLAN

Owner:

Team:

Action

Responsible

Start date

End date

Solution A2:
Action A2.1:
Action A2.2:

Name
Name

Date
Date

Date
Date

Solution B1:
Action B1.1:
Action B1.2:

Name
Name

Date
Date

Cause A

Generate potential solutions

Cause C

Cause D

Cause E

Completed?

Get approval

Team:

Root cause

Possible solutions (title and brief description)

Cause A

Solution A1
Solution A2
Solution A3

Cause B

Solution B1
Solution B2

Cause C

Solution C1
Solution C2
Solution C3
Solution C4

Date
Date

3c. SOLUTIONS APPROVAL TEMPLATE

3d. APPROVALS PLAN

Problem title:

Problem title:

Owner:

Solution title
Do it soon

B1.

Team:

Brief description

Owner:
Expected
impact

Required
investment

Team:

Time until
capturing impact

Who needs to approve

By when

Who is responsible for

getting the approval

Igor Boevski

16 June 2007

John Smith

A2.

Approval
received

3b. PRIORITISATION OF SOLUTIONS

Problem title:
Owner:

Team:

B2.

Do it soon

Legend (explanation of symbols)

Plan

High

A2
B2
B1

C2
C4

Impact

C4.

Do if there is time
Low

Do if there is
time

Plan

C2.

A1.

Skip
C1

A3

A1

C3

Low

Cause F

Problem title:
Owner:

Cause B

3a. IDENTIFICATION OF SOLUTIONS

4 Plan

Problem title:

Material

Method

High
Effort

A1:
A2:
A3:
B1:
B2:
C1:
C2:
C3:
C4:

Cause G

STOPPING THE BLAME GAME

Focus on problem itself, not who caused it

1 PROBLEM DEFINITION
Statement: Non Value Added time is 40%
p
Bad Example:
Reduce the non value added time

Good Example:
Reduce the non value added time due to walking from 2 hours per shift to 0,5
hours per shift within one month

KEY CRITERIAS
- Describe problem specificly
- Give Target
- Give
Gi e deadline

1a. PROBLEM DEFINITION

Problem title:
Owner:

Team:

Description of
problem to solve:

Current outcome:

Target outcome:

What is excluded
from the solution
solution
space:
4

1b. QUANTIFICATION OF PROBLEM

Problem title:
Owner:

Team:

Conclusion from
quantification analysis:

NVA time

_________

_________

_________

_________

_________

ROOT CAUSE ANALYSIS WITH THE 5 WHYs

1. Why did the machine stop?

Bearing is overheated!
Man
2. Why is the bearing
overheated? Has too little oil!

3. Why too little oil?

Pump doesnt supply enough oil!

4. Why doesnt the pump supply

enough oil? The filter is fouled!

5. Why is the filter fouled?

Maintenance interval too long!

Root cause of
th problem
the
bl

2a. ROOT CAUSE ANALYSIS THE FISHBONE

Problem title:
Owner:

Team:

Man

Machine

NVA time

Material

Method
7

2b. RANKING OF CAUSES

Problem title:
Owner:

Team:

Conclusion from
ranking:

% of NVA
time caused

Cause A

Cause B

Cause C
8

Cause D

Cause E

Cause F

Cause G

Speed fast / impact high

3 SOLUTION DEVELOPMENT

Problem

Primary cause

Man

Inspection criteria is
inconsistent among
inspectors

Excessive time
for cleaning to
remove rusts

Speed slow / impact low

Fifth cause
High variation of
criteria in determining
the occurrence of rust
Lack of approved
sample to be
compared or applied

Machine

Material

Lack of ant-rust
facilities on the shop
floor

Material is not flexible

and easily erodable

Tool is not suitable.

The drill for manual

work is revamped

Rust may easily

reoccur

Method

Rust can not be

removed manually

Manufacture samples
and approve

Anti moisture indoor

Anti-moisture
shop

Cleaning brush is
easily broken.

A lot of holes and thick

T/S

Countermeasures

Use elastic and antierodable material

Carbon material is
exposed

Close holes when

cleaned up

Contact with water

when removing oil

Change chemicals use

in removing oil

Lack of automatic tool

for exclusive use
Develop tools for
exclusive use

A lot of dust created

Apply tool using air

Speed of
implementation Impact

Speed fast / impact high

3 SOLUTION DEVELOPMENT

Speed slow / impact low

If you do a good root cause

analysis, then you can
easily develop
solutions Countermeasures
Primary cause
Fifth cause

Problem

Man

Inspection criteria is
inconsistent among
inspectors

Excessive time
for cleaning to
remove rusts

High variation of
criteria in determining
the occurrence of rust
Lack of approved
sample to be
compared or applied

Machine

Material

Lack of ant-rust
facilities on the shop
floor

Material is not flexible

and easily erodable

Tool is not suitable.

The drill for manual

work is revamped

Rust may easily

reoccur

Method

Rust can not be

removed manually

Manufacture samples
and approve

Anti moisture indoor

Anti-moisture
shop

Cleaning brush is
easily broken.

A lot of holes and thick

T/S

Use elastic and antierodable material

2 Prioritize the solutions

based
b
d on iimpactt and
d
easiness

Carbon material is
exposed

Close holes when

cleaned up

Contact with water

when removing oil

Change chemicals use

in removing oil

Lack of automatic tool

for exclusive use
Develop tools for
exclusive use

A lot of dust created

Speed of
implementation Impact

Apply tool using air

10

THINK LONG TERM

Implementing a Band-Aid

A Band-Aid is a temporary solution, to contain a problem

A countermeasure must address the root cause!

11

3a. IDENTIFICATION OF SOLUTIONS

Problem title:
Owner:

Team:

Root cause

Possible solutions (title and brief description)

Cause A

Solution A1
Solution A2
Solution A3

Cause B

Solution B1
Solution B2
Solution B3

12

3b. PRIORITISATION OF SOLUTIONS

Problem title:
Owner:

Team:

High
h

Do it soon

Legend (explanation of symbols)

Plan

A1
A2
A3
B1
B2
B3

A1
B2
A2

Impa
act

B1

Low
w

Do if there is time

Skip

B3

A3

Low

High
Effort

13

3c. SOLUTIONS APPROVAL TEMPLATE

Problem title:
Owner:

Do it soon
n

Solution title

Team:
Expected
impact

Brief description

A2
B2

Do if the
ere is
time

Pla
an

A1
B1

A3

14

Required
investment

Time until
capturing impact

3d. APPROVALS PLAN

Problem title:
Owner:

Who needs to approve

pp

Team:

Who is responsible for

getting
g
g the approval
pp

By
y when

15

Approval
received

4. PLAN WITH APPROVAL

Action

1 DEADLINE

2 RESPONSIBLE

Order new pipe

16 Feb 2008

Maintenance Engineer

Train new operator

10 Feb 2008

Supervisor

Review SOP

12 Feb 2008

Team with Prod. Mgr.

Approved by
Igor Boevski
16

Approval
received

4. IMPLEMENTATION PLAN
Problem title:
Owner:

Team:

Action

Responsible

Start date

End date

Action
A
i A1
A1.1
1
Action A1.2

Name
N
Name

Date
D
Date

Date
D
Date

Action B1.1
Action B1.2

Approved by
Igor Boevski
17

Completed?

STEP 5: IMPLEMENT THE SOLUTION

STEP 6: SUSTAIN
IMPLEMENT

SUSTAIN
TELL
TRAIN
MONITOR
CHECK

18

5. PROGRESS UPDATE
Problem title:
Owner:

Team:

Period:

Action

Status

Main highlights since

last review

Action A1.1
Action A1
A1.2
2
Action B1.1
Action B1
B1.2
2

19

Main challenges
g

Problem Solving

20

EXAMPLE

Trees should be mathematical correct

QC
Examples

? What is wrong?

Reduce number
of samples per
batch
Reduce
number
of tests

Avoid double
testing

QC tests for raw materials

from other Company sites

Use random sampling

Combine batches in one

delivery from supplier
to one batch for sampling

Install automatic
testing in production

Perform real-time
measurement of selected
parameters

Reduce number of
repeats

Establish robustness of
test to eliminate doubletesting of samples

Reduce
R
d
number
b off
independent tests

Reduce aspiration level

Eliminate activities

Install data base to

automatically coordinate
process changes

Increase efficiency

Replace newer technology

Eliminate activities

Transfer test results

electronicallyy to external
parties

Increase efficiency

Create order database

for tests outside regular
supply chain (e.g., R&D)

+
3

+
4

Reduce costs of
testing

Reduce number
of tests per
sample

+5
6

Reduce quality
control cost

Reduce
costs per
test

8
R d
Reduce
costs
t off
supporting tasks

21

Empty templates

22

1a. PROBLEM DEFINITION

Problem title:
Owner:

Team:

Description of
problem to solve:

Current outcome:

Target outcome:

What is excluded
from the solution
solution
space:
23

1b. QUANTIFICATION OF PROBLEM

Problem title:
Owner:

Team:

Conclusion from
quantification analysis:

_________

_________

_________

24

_________

_________

_________

2a. ROOT CAUSE ANALYSIS THE FISHBONE

Problem title:
Owner:

Team:

Man

Machine

NVA time

Material

Method
25

2b. RANKING OF CAUSES

Problem title:
Owner:

Team:

Conclusion from
ranking:

% of ________
caused

Cause A

Cause B

Cause C
26

Cause D

Cause E

Cause F

Cause G

3a. IDENTIFICATION OF SOLUTIONS

Problem title:
Owner:

Team:

Root cause

Possible solutions (title and brief description)

_____________

______________
______________
______________

27

3b. PRIORITISATION OF SOLUTIONS

Problem title:
Owner:

Team:

Plan

Do if there is time

Skip

Legend (explanation of symbols)

Low
w

Impa
act

High
h

Do it soon

Low

High
Effort

28

3c. SOLUTIONS APPROVAL TEMPLATE

Problem title:
Owner:
Solution title

Team:
Expected
impact

Brief description

Do it soon
n

______

Do if the
ere is
time

Pla
an

______

______

29

Required
investment

Time until
capturing impact

3d. APPROVALS PLAN

Problem title:
Owner:

Who needs to approve

pp

Team:

Who is responsible for

getting
g
g the approval
pp

By
y when

30

Approval
received

4. IMPLEMENTATION PLAN
Problem title:
Owner:

Team:

Action

Responsible

Start date

End date

____________

_______

_______

______

31

Completed?

5. PROGRESS UPDATE
Problem title:
Owner:

Team:

Period:

Action

Status

Main highlights since

last review

_________
_________
_________
_________

32

Main challenges
g