The Kaizen Workshop: from analysis to continuous flow

A Kaizen Workshop is an intense, action-oriented session that brings together a multidisciplinary team to dramatically improve a specific process in a short period of time (often a week). It is a powerful way to put the principles of continuous improvement directly into practice.

How does it work?

During the workshop, a specially assembled team, consisting of operators, line managers, executives and possibly consultants, goes through the following steps:

1. Observation and understanding: The team starts with a theoretical introduction to Lean, such as continuous flow. It then goes out onto the shop floor (gemba) to observe the current situation, identify waste and analyze the work flow.
2. Design and implementation: Based on the observations, the team designs a new, more efficient work cell. Machines and materials are relocated, and the new process is implemented immediately.
3. Testing and adjusting: The new setup is tested immediately. By experimenting and measuring, any problems are uncovered and necessary adjustments are made.
4. Standardization: Once the new process is functioning optimally, it is standardized. Clear work instructions and visual management ensure that improvements are maintained.
5. Reporting and assurance: Finally, the team presents the results achieved and the new standard to senior management, ensuring ownership and lasting impact.

The result is an immediately tangible improvement in efficiency, quality and turnaround time, realized by the people actually doing the work.

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