The Kaizen approach is a popular approach to value stream mapping. Ask yourself this question: How much time do you think you will take to complete a value stream map?
Mapping the value stream will take a long time if you don’t do it in a focused manner. Hence, it is like holding a magnifying glass in front of a specific point on a paper until it burns. If the point keeps moving and isn’t focused, the paper won’t burn. I have done this experiment in my childhood. The lesson to learn here is FOCUS. Hence, do not move until it burns!
What is Kaizen?
- Kaizen is a Japanese term. It means ‘change for the better’. It is synonymous with continuous improvement.
- In a current state value stream map, improvement ideas are shown as starbursts. These are also known as kaizen bursts.
- Kaizen events should be carried out in a blitz mode. Blitz means lightning fast. Therefore, most of the Kaizen workshops typically follow a 5-day schedule.
- The 1st day involves planning for change.
- The 2nd, 3rd, and 4th days involve carrying out change.
- During the 5th day, the team gets together to reflect on the ‘before and after’ status of the process.
- Kaizen teams aim to carry out Lean initiatives during the 5 days. Therefore, you could develop a ‘30-day action items log’ with a PDCA (Plan-Do-Check-Act) list. This will help you accomplish pending tasks after the Kaizen event.
Try to accomplish Lean initiatives in a focused and rapid manner. This helps keep the momentum and interests of stakeholders. The starbursts you see in the figure below represent improvement ideas. These include ideas related to reduced changeover time, reduced defects, reduced unplanned downtime, and increased availability.
Figure 1 – Kaizen – star bursts
Plan for a 5-day Kaizen event:
To give you an idea, find below a representative plan for a 5-day Kaizen event:
Figure 2 – A Kaizen Program Plan