Bài giảng Lean production systems - Chapter 10: Kaizen plans - Nguyễn Như Phong
8/13/2018
KAIZEN PLANS
GVC. ThS. Nguyễn Như Phong
Kỹ thuật Hệ thống Công nghiệp
ĐH BÁCH KHOA – ĐHQG TPHCM
(Tài liệu giảng dạy cho ISE)
2018
KAIZEN PLANS
Create Kaizen plans
VS Kaizen stages
Planning recap
Prepare for implementation
Implement Kaizen Plans
Recommendation 4 coping w. change
Keep the big picture in mind
Wrap up
Nguyễn Như Phong
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Create Kaizen Plans
Create detailed plan
guide efforts 2 improve the VS
wo. solid planning
slim chances 4 successful lean transformation
Nguyễn Như Phong
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Create Kaizen Plans
Schedule recurring meeting 2 ensure
Communication flows
All involved parties remain on the same pace
VS project status
In partnership w. VS champion
As milestone attained
Tools 4 highlighting concerns & potential solutions
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Create Kaizen Plans
Comprehensive planning
very important
but plans
not perfect
modified as
proceed through implementation
gain more practical experience w. L manu methods
Nguyễn Như Phong
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VS Project status: June 30
Schedule
Target completion date of 30/12
Accomplishments
Draft charter
Conducted training class on VSM
Modify PF 2 A & B only
ThS Nguyễn Như Phong
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VS Project status: June 30
Concerns (Issues)
Ability 2 maintain meetings at 3pm
Utilize a more planning tool 2 schedule improvement
Plan
Schedule meeting 4 1pm
Team leader 2 utilize KMW
4 detailed implementation of DFL focused kaizens
ThS Nguyễn Như Phong
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VS Kaizen stages
The monthly kaizen plan
Milestones:
Break the plan into manageable pieces
Complete the VSM storyboard
Catchball
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VS Kaizen stages
To increase the chances of success,
plan the implementation using the stages:
Plan how 2 ensure 2 meet CD
Plan how 2 improve the process flow
Plan how 2 level production
Planning sequence
most effectively & least costly
implementation of K plans
Nguyễn Như Phong
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VS Kaizen stages
K planning process steps
1. Review FSM
create a MKP
2. Determine milestones 4 each major K activity
create KMC
3. Complete VSM storyboard
4. Obtain management approval
for KPs through catchball
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The monthly kaizen plan
Plotting the implementation schedule
for the main elements / events
accomplished in each stage of FSM
Symbols 2 plot the timeframes
Open triangles – start dates
Dashed lines – expected duration
Closed triangles – completion dates
Macro-level sequence 4 implementation
MKP worksheet
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MKP worksheet
VS:
Date:
Schedule
Stage Event
J
F
M
A
M
J
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Milestones:
Break the plan into manageable pieces
Overall structure
for the main improvement events in place
Create a series of specific milestones for each event
Nguyễn Như Phong
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Milestones:
Break the plan into manageable pieces
Milestones
definable activities / tasks
required 2 accomplish the improvement
assigned completion dates
Eg.
Create a staging area in shipping
Install gravity racks at all supermarket locations
Establish production based on pitch
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Milestones:
Break the plan into manageable pieces
Kaizen milestone chart – KMC
Document & tract the completion of milestone
Show the sequence of
implementation activities
completion over time
Get down 2 next level of detail
Monitor activities on an ongoing basis
track progress toward completion
Nguyễn Như Phong
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Milestones:
Break the plan into manageable pieces
Things not always go according 2 plan
milestone achieved
earlier than planned
later than planned
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KMC
VS:
VS members:
June
Date: 15/9
July
Item
Task
Assìgn to
1
2
3
4
1
2
3
4
Demand
FGS
S
S
S
---
---
---
C
BS location
SS location
BS AMT
C
C
---
SS AMT
C
Ship Stage Area
C
Nguyễn Như Phong
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KMC
VS:
VS members:
Assìgn to June
Date: 15/9
July
Item
Task
1
2
3
4
1
2
3
4
Flow
Machning supermarket
Line balance
S
C
S
---
C
Gravity racks
S
---
S
C
---
---
Kanban address
Restricted FIFO lane
Standardized work
Quick CO assembly
Pitch establish
---
---
S
---
---
S
C
C
C
C
---
S
---
S
---
S
---
Machining programming
---
C
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KMC
VS:
VS members:
August
Date: 15/9
September
Item
Task
Assìgn to
1
2
3
4
1
2
3
4
Leveling
Heijunka box
Runner route
Team Recognition
S
S
---
---
---
C
C
All
C
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Complete the VSM storyboard
Time 2 complete the VSM storyboard
Add
Proposed monthly Kaizen plan
Any other data overlooked earlier
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PM CASE
Kaizen proposal
2001
1st 2nd 3rd 4th
Demand- Establish BSS, FGS, implement 5S
S
S
C
C
S
S
S
Flow – Cell design. Line balancing. Standardized work
Flow – Reduce CO. implement AM
Level – establish runner route
C
Level – Implement Heijunka & kanban sys
C
Level – Additional TPM application: modify PM standards
Started - Complete - Past Due
Nguyễn Như Phong
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Catchball
Time 2
play catchball
get buy-in 4 the plans
Presenting the plan 2 high-level managers
gain approval 4 the plan
Smooth Catchball process
The FS planned carefully
Careful thought to
how the plan implemented systematically
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Catchball
Prepare 4 the UM meeting
Why implementing lean in this VS
What impact on customers
What quality improvement achieved
What cost saving achieved
What LT reduction achieved
How relate 2 strategic objectives
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Planning recap
Planning primarily about managing action
Guidelines 4 effective K planning
Be realistic
Play catchball
Be detailed
Communicate
Make it visual
Recognize good work
Be sure 2 celebrate
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Prepare for implementation
Plan carefully – minor adjustment 2 the plans
Make whatever modification required
then prepare 4 the implementation
Various members of the implementation team
lead a series of K events
make the changes necessary 2 transform the VS
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Prepare for implementation
K events
A team event
dedicated 2 quick implementation of L manu method
in a particular area
over a short time period
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Prepare for implementation
Main points of preparing K events
Identify clearly & communicate the E objectives
Identify any training
Define the scope
Register the team by team charter
Use the KMC 2 determine event completion date
Prevent problems
Draft the agenda 4 the duration of the event
Nguyễn Như Phong
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PM CASE
Implementation agenda
VS: A&B
VS Stage: Demand
Event date: May 17-18
Kaizen event objective: Estabish a FGS sys
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PM CASE
Implementation agenda
Day 1
Welcome & intro
Review VSM storyboard
Adjust any parts of the demand FS
Identify any issues
Walk the actual flow as defined in the FS
Conduct training on supermarket & kanbans
Begin analysis of kanban flow & conduct kanban calculation
Nguyễn Như Phong
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PM CASE
Implementation agenda
Day 2
Begin setting up stores
Create KCs
Set up address locations 4 the supermarket
Determine list & color code sys 4 store
Trial K sys
Collect data & monitor
Review data
Write initial supermarket & kanban procedure
Update job descriptions
Update internal procedures
Monitor
Set plan 2 standardize within 1w
Team recognition
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Prepare for implementation
Team recognition
Transform a VS 2 its FS
may take a year or longer
People
work long periods wo. feeling appreciated
bound 2 loose focus & enthusiasm
Nguyễn Như Phong
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Implement Kaizen Plans
Planning & preparation done
Proceed 2 the implementation phase
Enthusiasm & confidence
Kaizen activities
When implementation begins in earnest
impact on virtually everyone connected 2 the VS
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Recommendation 4 coping w. change
Change
even 4 better
difficult 4 most people
The more people know about what going on
the easier 2 deal w. anxieties
accompanying significant change
Nguyễn Như Phong
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Recommendation 4 coping w. change
Communicate
Address negative behavior early in the implementation
Not let the problem stop the process
Consider each kaizen event an experiment
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Recommendation 4 coping w. change
Reward & recognize people’s efforts
practice mutual trust & respect
treat people w. honesty & integrity every day
Be present
Be flexible
Nguyễn Như Phong
11 April 2003
Keep the big picture in mind
Keep the big picture in mind as progress
Refer 2 the storyboard frequently
2 explain 2 people how using VSM process
Fast, flexible process
Be patient & realistic
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Wrap up
Continually to look for ways
to improve the entire VS
Nguyễn Như Phong
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