How To Conduct A Kaizen Blitz

How to Conduct a
Kaizen Blitz
Darcy Priest – Veris Production Manager
Jan 5th, 2005

What is a Kaizen Blitz?
A Kaizen Blitz aims to quickly analyze and implement lean principles on a cellular or subcellular level.
Conducting Kaizen Blitzes in all areas of a production line is the basis of lean implementation.
“Kaizen” is Japanese for continuous improvement, which means lean implementation is a continuous process! Name of the presentation (Edit in Foo

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What is involved?
A Kaizen Blitz consists of the same key components as lean implementation:
 Standard hour and cycle time analysis
Value stream mapping
Root cause analysis

 Process and flow analysis
Kanban implementation
Single piece flow

 Layout analysis
 5S implementation

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The Kaizen Blitz Process
Every Blitz is unique, but the key steps are:
 Build a team that is focused and trained in the key lean elements
4-8 people max trained in 5S, cycle time and process analysis

 Define the scope and set a clear purpose
Determine any key outcomes or constraints

 Set the objectives
Be SMART – Specific, Measurable, Achievable, Relevant, Timely

 Analyze existing process and cycle time
Think value add, map the process steps, chart cycle time, material flow

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The Kaizen Blitz Process
 With the original objectives in mind, optimize the following:
Cycle time
Material flow
Inventory/WIP
Cell layout
5S
Visual workplace

 Implement the changes
 Measure gains from short term changes against original objective

Remember the change process: Where are we?
Where do we want to go? How do we get there?
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Build the Blitz Team
 The size and skill level of the team can greatly impact their effectiveness If the scope has been properly set, no more than 8 people are required in the core team
An even representation of team lead, engineering, support, and production people must be maintained to ensure