Lean Kaizen Techniques for Pharma

The pharmaceutical industry is undergoing a transformation where Six Sigma, lean, and kaizen methods can be used to instill the discipline necessary to achieve operational efficiencies and accelerate new product development. This article discusses techniques for blending the methodologies in the improvement process, such as the project charter and selection steps. ...

... "One approach is to integrate the chartering activity from the Six Sigma roadmap at the outset of the Kaizen blitz. The chartering exercise is crucial at the beginning of a Lean Kaizen in order to establish clear project success metrics, definition, expectations, communication, and milestones. " ...

Via Pharmaceutical Processing: Lean Kaizen

Kaizen Change Empowers Shopfloor

TriMas Corp embraces kaizen principles as it shifts accountability for continuous improvement to shopfloor workforce. ...

... "In 2006 it was the inaugural winner of the Toyota Kaizen Blitz Marathon for reducing waste levels. The changes generally happen in a short order of time, Mr Saunders said. And from the perspective of management it empowers people doing the job to make a change. Kaizen change is driven by shop floor or office employees. " ...

Via Star News: TriMas Corp Goes Lean

Government Kaizen Initiative

Local authority uses kaizen methods to improve services and their success is recognized. ...

... "Following recognition at national level, Aberdeenshire Council's Kaizen initiative is now a beacon of excellence across Europe after taking an international award for continuous improvement.

The Aberdeenshire approach on this theme is based on the Kaizen model. Kaizen is a Japanese expression meaning making something as good as it can be and the process engages teams of employees in concentrated blitzes to identify more efficient ways of working. The exercise has been driven by Chief Executive Alan Campbell and his Senior Management Team since 2004, and is supported by facilitators in all of the council services and Kaizen Champion Pat Browne. For each blitz undertaken, a team leader is appointed and in turn selects a team of between 10 and 14 people who are close to the process to be improved. " ...

Via Aberdeenshire Council: Aberdeenshire Blitzes competition to take European award ...

Kaizen Blitz Momentum Builder

Navy accelerates momentum in AirSpeed lean practices through increase the volume of kaizen blitz events. ...

... "Q: How do we increase mass in AIRSpeed? A: Through kaizen blitz - multiple rapid improvements done by multiple participants simultaneously. " ...

Via Kaizen 10 in 10: building AIRSpeed momentum

AirSpeed kaizen reference ...

NAVAIR AIRSpeed Definitions: "Kaizen is a method for accelerating the pace of process improvement in any setting. It is typically a rapid (1 week or less) intense event where progress is made through all of the Define-Measure-Analyze-Improve-Control steps. This requires preparatory work completed on the Define step and even sometimes the Measure step by a small team led by a team leader and a Black Belt. The rest of the work is done by a full group where the participants work ONLY on the project and are relieved of responsibilities. "

Kaizen Blitz Investment ...

Investment sought to continue with kaizen blitz to drive operational efficiency ...

... "This will include strengthening the authority's highly-regarded Kaizen Blitz team, which develops ways of efficient working; " ...

Kaizen Blitz Investment: Via The Buchan Observer: Council Tax bills to rise by 4.5% ...

Kaizen Blitz: Improvement Technique ...

Business, everywhere, can benefit from continuous improvement. Products, processes, and people can improve quality. Fred Fishman, Manager Strategic Procurement Programs, explores the techniques of continuous improvement, such as recognizing the opportunity and seeking assistance. ...

... "Whether portrayed in a formula-rich analysis during a Six Sigma event, the rapid fire and instinctive physical changes implemented during a kaizen blitz, the reduction of muda (Japanese term for waste) in the lean journey, or the methodical development of a value stream map to visually identify value-added vs. non-value-added steps in a flow of work, each technique employs some variation of mathematical, statistical or visual analysis to achieve the desired result - improvement. " ...

Kaizen Blitz: Improvement Technique: Via Reliable Plant Magazine: The importance of Continuous Process Improvement ...

Kaizen Efficiency Improves Customer Experience ...

IBM white paper explores the efficiency in business models which will improve the customer experience, such as the kaizen blitz process at Lexus. ...

... "Luxury car manufacturer Lexus designs customer experiences that personify its brand statement and support its customers' aspirations, Lexus, the passionate pursuit of perfection. For example, dealerships maintain spotless service bays and they operate on the Lexus principle of kaizen - Japanese for continuous improvement. " ...

Kaizen Efficiency Improves Customer Experience: Via Line56.com: IBM's Paradox of Banking 2015

Kaizen Strategy: Lean Manufacturing

Waste Minimization: Lean Manufacturing

... "The kaizen strategy aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process. The team uses analytical techniques, such as Value Stream Mapping, to quickly identify opportunities to eliminate waste in a targeted process. The team works to rapidly implement chosen improvements (often within 72 hours of initiating the kaizen event), typically focusing on ways that do not involve large capital outlays. Periodic follow-up events aim to ensure that the improvements from the kaizen blitz are sustained over time. Kaizen can be used as an implementation tool for most of the other lean methods." ...

Kaizen Blitz Involves Workforce ...

Lean Manufacturing - Kaizen Blitz - Involve Your Workforce in the Pursuit of Eliminating Waste ...

... "What is Kaizen Blitz? A Kaizen Blitz is an intensive and focused approach to Process Improvement. Kaizen means continuous improvement and Blitz means lightning fast. This continuous improvement methodology combines lean manufacturing tools such as the 5S's of Workplace Organization and Standardization, Cells, Pull/Kanban, Setup Reduction and Line Balancing. Each tool incorporates team empowerment, brainstorming and problem solving to rapidly make improvements to a specific product or portions of your processes." ...

The Kaizen Event methodology has been used extensively for improving the organization of work in factories and actual methods used to manufacture products. The results are real-time with implementation occurring within one week.

Continuous Improvement Kaizen Blitz ...

Quick and continuous improvement through kaizen blitz ...

From Hosp Mater Manage Q, McNichols T, Hassinger R, Bapst GW write ...

... "It is our objective to provide you with a step-by-step approach to conducting a kaizen blitz within two days and describe how to achieve dramatic performance improvement with employee buy-in through this process. Kaizen blitz has been used dozens of times by the authors, and in some instances the same area has been blitzed as many as four times, with significant improvements each and every time. Employees have even taken it on themselves to conduct informal blitzes as a continuing improvement effort after a formal blitz has been conducted in their area. Blitzes can succeed in a variety of environments. The morning after the employees of one company attended this presentation, they self initiated a mini-blitz and discovered opportunities for improvement that they enthusiastically presented to management." ...

Waste Minimization Kaizen Methods ...

Waste Minimization: Lean Manufacturing ...

From EPA ...

... "Kaizen, or rapid improvement processes, are often considered to be the building block of all lean production methods. Kaizen focuses on eliminating waste in the targeted systems and processes of an organization, improving productivity, and achieving sustained continual improvement. This philosophy implies that small, incremental changes routinely applied and sustained over a long period result in significant improvements. The kaizen strategy aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process. The team uses analytical techniques, such as Value Stream Mapping, to quickly identify opportunities to eliminate waste in a targeted process. The team works to rapidly implement chosen improvements (often within 72 hours of initiating the kaizen event), typically focusing on ways that do not involve large capital outlays. Periodic follow-up events aim to ensure that the improvements from the kaizen blitz are sustained over time. Kaizen can be used as an implementation tool for most of the other lean methods." ...

Kaizen Blitz: MEP Source For Manufacturers

From the Manufacturing Extension Partnership MEP ...

... "A Kaizen Blitz is an intensive and focused approach to Process Improvement. Kaizen means continuous improvement and Blitz means lightening fast. This continuous improvement methodology combines lean manufacturing tools such as the 5S's of Workplace Organization and Standardization, Cells, Pull/Kanban, Setup Reduction and Line Balancing. Each tool incorporates team empowerment, brainstorming and problem solving to rapidly make improvements to a specific product or portions of your processes." ...

MEP stands for the Manufacturing Extension Partnership. MEP is a nationwide network of not-for-profit centers in nearly 350 locations nationwide, whose sole purpose is to provide small and medium sized manufacturers with the help they need to succeed. The centers, serving all 50 States and Puerto Rico, are linked together through the Department of Commerce's National Institute of Standards and Technology. Centers are funded by federal, state, local and private resources to serve manufacturers. That makes it possible for even the smallest firms to tap into the expertise of knowledgeable manufacturing and business specialists all over the United States. These specialists are people who have had experience on manufacturing floors and in plant operations.

Kaizen Blitz: Maintenance In High-Tech Industries

From Industrial Maintenance & Plant Operations, Nancy Syverson, Managing Editor, writes ...

... "This includes training the entire workforce in lean manufacturing and one-piece flow. On a regular basis they also conduct kaizen blitzes, always with representation from maintenance. " ...

Aid for Kaizen Events: New Booklet Offers 111 Valuable TIPS for Lean Manufacturing

From Emediawire (press release) ... Manufacturing. Lean Leaders and Lean team members will find this booklet particularly useful during Kaizen Events or Blitz Weeks. ...

... Joe Rodriguez, Principal of Global Innovation Leadership, Inc has published a booklet titled, 111 TIPS for Lean Manufacturing. Lean Leaders and Lean team members will find this booklet particularly useful during Kaizen Events or Blitz Weeks. ...

Organizations that have relied on Global Innovation Leadership to improve their operational efficiency, innovational abilities, staff performance, leadership skills, and competitive viability in global markets. GIL's clients range from small manufacturers to Fortune 500-ranked businesses and institutions.

This booklet covers 111 tips to help you implement "Lean Manufacturing" much faster. The tips are split into 10 tips per topic area and we cover the 11 key areas of Lean. The Topics are; Lean Thinking, Waste Elimination, Continuous Flow, Quick Set Up, 5S, TPM, Production Control, Visual Management, Error Proofing, Process Improvements, and Suppliers. Lean leaders and Lean team members will find these ideas useful and easy to implement. A particularly practical booklet to provide each team member with during Blitz week.

New Lean Manufacturing Book: Kaikaku The Power and Magic of Lean - A new book on Toyota's ...

From Emediawire (press release) ... "Norman Bodek is the secret weapon of lean manufacturing. In his 59 trips to Japan, Norman met Shigeo Shingo, Taiichi Ohno and other ...

PCS Press is a publishing, consulting and training company focusing on improving customer service, quality, and human value. Offices are at 809 SE 73rd Ave., Vancouver, WA 98664, 360-737-1883

NORMAN BODEK, bodek@pcspress.com, Norman Bodek is president of PCS Press, a Vancouver, Washington, publishing, training, and consulting company. He discovered and published the works of the truly great Japanese manufacturing geniuses: Dr. Shigeo Shingo and Taiichi Ohno, the inventors of the Toyota Production System now called JIT and Lean manufacturing and many others. From his numerous trips to Japan he introduced to the western world the Kaizen Blitz, SMED, TPM, QFD, Hoshin Kanri, Poka-Yoke, Visual Factory and other new manufacturing methodologies that have helped companies improve their quality, and productivity. In 1988 he initiated the Shingo Prize for Manufacturing Excellence with Professor Vern Buehler at Utah State University. Most recently he co-authored a book with Bunji Tozawa titled The Idea Generator - Quick and Easy Kaizen. The Quick and Easy Kaizen system recognizes that every worker has hidden creative talent locked inside. This system becomes a powerful tool for management to bring forth lots and lots of small but significant improvement ideas from all their employees. The employee becomes empowered to make changes to improve customer service, to make their worker easier and more fun, to improve quality, to reduce costs, and to improve safety. And it works!

Lean Kaizen: Kaizen Blitz Workshop...

From Bulltek ... This workshop have been implemented within the automotive sector which provided a continual basis to paradigm shifting where teams are implementing on going new improvements.

The workshop:

What is Kaizen (and what is not)
Identification, evaluation, and analysis for implementation improvements team focused: Transfer of tacit knowledge; Identification of solution and opportunities; Tackling improvement and opportunities through sub-teams analyzing opportunity or problem; Deciding on best path and blitz implementation; Identifying and defining what's to implement immediately, short and medium range; Discussion with management on the improvement in terms of $$.

Further continuing with:

Employee involvement
Kaizen and Blitz principles involving identification, knowledge sharing, and evaluation based on principles compatible with stopping, reduction, and changing managerial system focus providing the fundamentals for consciousness, continuity, involvement; This is all within a week of teamwork.

Since 1984 BULLTEK LTD has tailored its services assisting in competitiveness, reduction of risk, and technology. We focus our collaborative teamwork by addressing the complex business challenges faced by global clients. Through our GlobalNet (of selected professionals, associations, universities, joint ventures, and partners) we have grouped a highly competent network of services, professionals and technologies continuously enhanced focusing on industry, global, regional "best practices", and security while prioritizing on informative content and support.

Kaizen Techniques...

Kaizen, or rapid improvement processes, often are considered to be the ‘building block" of all lean production methods. Kaizen focuses on eliminating waste in the targeted systems and processes of an organization, improving productivity, and achieving sustained continual improvement. Lean production is founded on the idea of kaizen - or continual improvement. This philosophy implies that small, incremental changes routinely applied and sustained over a long period result in significant improvements.

The kaizen strategy aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process. The team uses analytical techniques, such as Value Stream Mapping, to quickly identify opportunities to eliminate waste in a targeted process. The team works to rapidly implement chosen improvements (often within 72 hours or initiating the kaizen event), typically focusing on ways that do not involve large capital outlays. Periodic follow-up events aim to ensure that the improvements from the kaizen "blitz" are sustained over time.

Kaizen can be used as an implementation tool for most of the other lean methods...