Workshop Training Packages Can Improve Your Kaizen Events

Anyone who has worked with Lean is familiar with the term Kaizen, a Japanese word roughly translated into English as ‘Continual growth and improvement'. This is a core concept in Lean for the simple reason that without it, any system will quickly stagnate and fail.

The designers of the Toyota Production System looked much deeper than just ‘how to build a car faster', they researched the practices and habits that lead to good productivity and those that result in bad productivity, and embedded the good practices into their system. And one key element, often left out of other systems, was what they termed Kaizen.

However, one of those bad practices which pop up frequently is to ignore Kaizen and just sit back and enjoy the benefits of the improvements that have just been implemented. This is part of human nature, but not necessarily the best part.

Kaizen Events:

Built into this system is the need for regular Kaizen events, even if there are no major changes scheduled for the current business cycle. These events are critical to maintain both company morale and the focus on productivity that is required to keep the system on track.

Kaizen Events come in two basic forms:

• Full Kaizen Event: This is a large scale event usually involving a significant portion of the work force, if not the entire company. It is put together by a special committee which is also responsible for deciding what new implementations are to be scheduled in the coming year. A Kaizen Event generally accomplishes:

• Review: A discussion of the most recent initiative and what was accomplished. This usually includes an opportunity for the attendees to add their own opinions and observations.
• Refresher: A chance to touch up and sharpen key skills and concepts that may be losing strength.
• Reorientation: A chance to get the group more strongly aligned with Lean program as whole and recent changes in particular. This is a good opportunity to address in a low key way the barriers to progress that may crop up from time to time.
• Announce: This is an excellent opportunity to outline the next initiative and preview what changes and benefits are anticipated. Note: even if you are not scheduling an initiative, you should be having events on a regular basis.

• Kaizen Workshop: A smaller scale event, usually addressing teams or departments or other small groups. It is designed to focus on specific areas involving:

• Morale: Problems causing friction in the ranks.
• Skills: Specific skill sets that have lost their edge.
• Attitude: Attitudes that are interfering with the proper progress of the system.

Training:

Of all the elements in a Kaizen event, the one most likely to get underused is the opportunity for group training exercises. When incorporated into a pleasant and diverting program, you not only sharpen skills but, if done properly, can improve morale.

Enna.com has some training kits that are particularly useful in programs like these:

• Workshop packages: Workshop training packages are in depth training materials that come complete with sample forms, illustrated study materials and a training format. They cover basic skills and concepts like 5S, or can introduce more advanced initiatives like SMED Quick Changeover.
• Quick Learning lean kits: For a less intense experience, these easy to use Quick Learning lean kits can help you create a fast, entertaining training session for a variety of skills.
• Games: There is always a place for fun in a Kaizen event, and these training oriented games are just the thing.

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