Experience, hands-on, the five-day Kaizen Event that is one of the most critical tools to generated rapid sustainable Lean improvement. The Classic Kaizen Workshop Solution Package will engage your business teams with proven techniques for creating dramatic improvement, streamlining manufacturing and business processes. We have put all the experience needed in this package to confidently lead your own Kaizen Event.

As a facilitator of a Kaizen workshop you will discover first-hand the dramatic manufacturing and business process efficiencies and bottom-line improvement you can quickly achieve and sustain in your own business. The Classic Kaizen Training Package will guide you through all the steps to generate immediate improvement and cost savings. You will experience radical reductions in process cycle times, increased throughput, elimination of waste and bottlenecks, and improved morale and safety. This five-day workshop is structured around one day of training and four days of implementation. If you are considering a Kaizen Event this training package is perfect for you.

Use of Training Package

Use this training package when you are focusing on more than a specific machine. Classic Kaizen is meant for workshops that involve people, materials, information and machines. To determine this ask if there are “hands-on” activities. If there are then this package will meet your requirements. This package is perfect for the following departments; final assembly, painting, packaging, sanding, profiling, fitting, warehousing, shipping and more.

Kaizen Workshop Training Outline

Introduction

• Scheduling Workshops
• Goal Setting

1. The Lean Approach

• Purpose and Reason for Kaizen
• New Economies
• Brief History of Lean

2. Daily Improvement Method

• Achieving Kaizen Mindset
• Workshop Structure

3. Fundamentals of Kaizen

• Three Elements of Work
• The Seven Wastes

4. One Piece Flow Simulation

• Principles of Flow
• Benefits of One Piece Flow

5. Kaizen and 5S

• Yin and Yang of 5S & Kaizen

6. Workshop Process

• Structure of Kaizen Workshop
• Kaizen Analysis
• Review of Forms

The Classic Kaizen Workshop contains the following:

• Classic Kaizen Facilitator Guide (1) – A comprehensive step-by-step review of the presentation and workshop that leads the Facilitator effortlessly through entire event.
• Classic Kaizen Preparation Guide (1) – The Preparation Guide, available only with the solution package, contains a systematic approach to preparing and executing a flawless Kaizen Blitz workshop. Use as a reference manual for time, scheduling, and overall flow of the workshop.
• Classic Kaizen Facilitator Digital Media (1) – A high resolution training focal point that links the Facilitator Guide to the Participant Workbooks. This presentation is designed with Flash Technology instead of Power Point in order to obtain the highest clarity and sharpness of images possible. The presentation loads onto all Windows-based computers.
• Classic Kaizen Participant Workbook (8) – Designed for the participants, this workbook reinforces ideas presented by the Facilitator and can be retained for future reference. The workbook contains illustrations, key questions, and space for personal note taking; it also contains a self-assessment form to test participants on key principles outlined in the presentation.
• Standard Worksheet (1) – An 11 X 14 pad of forms that presents the work sequence, takt time, processes, and workcell layout.
• Standard Combination Worksheet (1) – An 11 X 14 pad of forms that allows you to chart the takt time of work sequences for a single worker doing standard work.
• Time Bar Graph (1) – An 11 X 14 pad of forms that creates detailed time graphs for different products and processes.
• Time Observation (1) – An 8 1/2 x 11 pad of forms that is used to track the average takt times for each step of a particular process.
• Distance and Tasks Graph (1) – An 11 X 14 pad of forms for charting tasks and distance traveled to make it easier to diagram the flow.
• 7 Wastes Observation Form (1) – A pad of template forms; the form is used as an analysis tool for assessing opportunities for elimination of wastes in each department.
• Motion Diagram Form (1) – An 11 X 14 pad of forms used to model motion during machine setup or changeover of model type. A great visual tool for demonstrating amount of travel.
• 5S: Map (1) – This 11x14 form has a dual purpose: to provide a current state map at the beginning of the workshop and a revised current state map at the end of the workshop.
• 5S: Red Tag Register (1) – An 11 X 14 pad of forms; this form tracks and logs each 5S red tagged item, its classification and the course of action to be taken regarding the red-tagged item. It provides a focal point of control and reference for tracking movement of materials and equipment.
• 5S: 30 Day Action Log (1) – This 11x14 pad of forms is the center of communications for 5S problems discovered during the workshop that cannot be solved immediately. The 30 day Action Log describes activities, assigns responsibility for completion, and provides possible solutions to the discovered problems.
• 5S: Evaluation Review Form (1) – An 11X14 pad of forms that is essential for 5S activity and setting benchmarks for work areas in order to provide an objective measurement. This form assesses all 5S steps; Sort, Straighten/Set in Order, Sweep/Shine, Standardize, and Sustain.
• 5S: Red Tags (50) – Red Tags are used to keep the process of change going throughout the 5S workshop while remaining organized in the process. Also available on manila-colored stock for compliance with ISO Standards.
• Kaizen: Poster (1) – Full color reminder of how to successfully grow through Kaizen.
• 5 S's of Kaizen Poster (1) – This poster reinforces the building blocks of Kaizen with eye-catching graphics and clear, concise summaries.
• 7 Wastes of Operations: Poster (1) – A full color visual aid to be used during Kaizen training and posted in work areas to remind staff to continuously eliminate waste.
• Commandments for Continuous Improvement Poster (1) – A full color poster to support your Classic Kaizen Workshop. It encompasses the fundamental philosophy behind Kaizen while reminding participants how to problem solve as a team.

What is the difference between the Classic Kazien Workshop and Quick & Easy Kaizen Solution Packages?

• The Quick and Easy Kaizen Solution Package is focused toward introducing, building, and managing an employee suggestion system for improvements. The Classic Kaizen Workshop is designed to implement kaizen in a work area during an improvement workshop to significantly improve an area.

What is the difference between the Classic Kaizen Workshop and Lean Manufacturing Workshop training packages?

• The difference between the two packages is with the terminology used in the materials, such as the training materials, posters and forms.
• Simply choose the term, Kaizen or Lean, which your company uses and start using our process improvement implementation tool today.

What is in your Kaizen Blitz Workshop package?

• Our Package includes one Facilitator Guide, one digital media CD, one kaizen event preparation guide, 4 different kaizen posters, eight participant workbooks, and 13 different kaizen forms including 5s red tags.

I am in charge of the kaizen (continuous improvement) program in my facility; how will your package help me do my job?

• The Kaizen Workshop Solution Package will assist you in:
• Training employees
• Involving your employees in a kaizen event
• Increasing productivity
• Reducing manufacturing lead times
• Lowering work in process inventory
• Increasing first pass yield and throughput
• Enna’s kaizen program is easily scalable and reusable. The Classic Kazien Workshop Refill Packs may be used to expand your kaizen training program to implement kaizen in every area of the plant including the offices/administration areas.

Should I have a workbook for each participant?

• Enna recommends purchasing a Classic Kaizen Participant Workbook for each person involved in order to maximize their experience. The workbook is integral to the presentation and workshop as it provides insight, suggestions, asks key questions and includes a self-assessment form to solidify retention of main concepts. It also allows employees to document their experiences, and may be used as a reference tool after the training and workshop has ended.

Why should I use Enna’s Kaizen Workshop Solution Package instead of other Lean or Kazien Training products?

• Enna products are high quality and provide the greatest value for your dollar. Other companies’ products do not compare in quality, format of information and/or are not designed for the actual implementation and sustainment of continuous improvement programs. Enna products are designed with the concept of “Knowledge into Practice™”.

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