RWD’s rapid improvement event
training is a continuous improvement methodology that follows the PDCA cycle
(Plan, Do, Check, Act), in a Kaikaku event format. It is intended to help the
whole organization make a quick improvement in a target area. The event
training is conducted in a 5-day timeframe; participants receive training on
lean philosophy and the improvement event process. Participants then conduct a
waste walk to look through “new eyes” at their own workplace. The following
days are spent improving the work area through:
- Problem Solving
- Standardization
- Line Balance
- New Layout
- In-station Quality
- Quick Changeover Applications
- 5S
- Visual Factory Implementations
The Kaikaku or rapid improvement
process will give your leaders and staff the opportunity to begin solving
problems immediately, while they are still learning concepts and tools.
“Kaizen” vs. “Kaikaku”
The word Kaizen is a Japanese word
meaning “small change” which is a philosophy based on the premise that no
matter how long or how effective a process has been in place, it can be improved.
This type of thinking is one of the principles of the Toyota Management System
that has been used by Toyota to drive waste out of their systems for years,
with every employee daily focused on “continuous improvement”. Kaikaku, conversely, is a radical overhaul of
an activity to eliminate all waste (“muda” in Japanese) and create greater
value. Also sometimes called breakthrough kaizen, a “Kaikaku Event” is a
focused short-term effort to achieve a significant change in a small amount of
time.
A typical “Kaikaku Event” will last
for a short period of time usually 10 days or less. It is designed to remove
roadblocks, garner ideas from the area team members, trial the changes, and
encourage team problem-solving. The event is purposely kept short to keep the
focus on actually completing the work versus planning for it. During the event
members will generate a great number of ideas and concepts. RWDs lean coaches ensure event planning
execution and follow-up are conducted to drive the specific results outlined
before the event.
Direct improvements in the
following areas are targeted in a rapid improvement event:
- Safety performance
- Productivity
- Product Quality
- Materials and Supply Cost
- Overtime Reduction
- Delivery reliability
- Asset uptime