course | Implementation of Kaizen in the Production Floor

Introduction to Kaizen:
 

• The concept of continuous improvement management.
• Understand KAIZEN in Japanese.
• Development History of the Japanese strategy for continuous improvement (KAIZEN).
• Kaizen benefits for production processes: Case Studies.
• How does the Japanese KAIZEN strategy work?
• KAIZEN'S relationship with the DEMING CYCLE.
• A comparison between KAIZEN and the rest of the continuous improvement processes (TQM, TPM, QC, SIX SIGMA).
• Strengths of the KAIZEN program.
   

Your Guide to Understanding Kaizen Tools:
 

• Check Sheet.
• Pareto Chart.
• 7QC Tools and their Application.
• Histogram.
• Scatter Diagram.
• Process Map.
• Cause and Effect Diagram.
• Process Map.
• Control Chart.
• Root-cause analysis.
• Fishbone Method.
• (ISHIKAWA).
• Five-question style.
• (5 WHYS).
• Optimization-based processing method.
• Workshop.

Developing Kaizen Strategy:
 

• Introduction of Kaizen Strategy.
• How to Plan for a Kaizen Continuous Improvement Programme?
• Design the Kaizen Culture.
• Developing a Kaizen Roadmap.
• Planning and Organising Effective Kaizen Events.
• Selecting and Handling Projects.
• Kaizen Teams formation strategy.
• The Roles of Team Members.
• Performance Metrics.
• Understand Kaizen PDCA.
   

Mapping of Process and Value Stream

• Process Mapping Overview.
• Understand Value Stream Mapping Principles and Methodology.
• Mapping Tools and Symbols.
• Using Process Maps.
• Understand and apply Value Stream Maps.
• How to Prioritise and Select Kaizen Projects.
• Strategies for Developing a Project Charter and Project Plan.

Implementing of Kaizen Project:
 

• Identify the Kaizen Project.
• The structure and steps of the Kaizen Project.
• Prepare the Kaizen Event.
• Understanding Workplace Kaizen.
• Map the Current State for the Kaizen Project.
• Identify Areas for Improvement.
• Map Future State.
• Cost and Benefit Analysis of Projects.
• Implementing Future State Improvements.
• Post-Project Review and Follow-Up.
• Identify Further Areas for Improvement/Skills Development.
• Project Presentation.

Practical Application: Implementation of Kaizen in the production floor:
 

• Applied tools for the continuous improvement process according to the KAIZEN strategy methodology
• How can we eliminate overproduction?
• How can we improve manufacturing quality?
• How can we make manufacturing more efficient?
• How can we remove unneeded steps in manufacturing?
• How can we eliminate errors in the final product?
• Practical applications on industrial processes using kaizen.
• Practical applications of office and administrative operations using kaizen.