Continuous Flow Manufacturing
Kaizen Blitz 

            A Kaizen Blitz is a very intensive and focused approach to Process Improvement.  A specific process is selected for analysis by a multi-functional team of people.  The team defines the current process by use of flow charting, process mapping, process performance measures, and process observation.  Thereafter, the team re-designs the process in such a way that will result in substantial improvements in most, if not all process performance measures.  Whenever possible, elements of the new process are implemented during the Kaizen Blitz, and the results verified.

This approach can be used to implement Continuous Flow Manufacturing concepts in a production operation.  A three (3) day Kaizen event is conducted in the production area.  A team of internal personnel is identified, and is facilitated through an eight step approach to implement Continuous Flow Manufacturing concepts.  Education in Continuous Flow Manufacturing concepts is a part of the event.  When circumstances allow, the new process is actually implemented and the results verified.  When not possible, the organization is left with: a layout of the proposed process; projected performance measures for the new process; detailed work station designs; an implementation plan and actions list.  Approximately 75% – 80% of all events result in actual physical changes by the end of the three (3) day Kaizen Blitz.

The process performance measures that are used are as follows (along with typical results):

• Cycle Time             –           up to 95% reduction
• Distance Traveled   –           up to 80% reduction
• Space Utilization     –           up to 70% reduction
• Work-in-Process    –           up to 90% reduction
• Productivity            –           up to 40% increase
• Quality Yields         –           25% – 75% increase 

Typical Three (3) Day Agenda

Pre-event:

• Scoping – identify product family to be subject of event
• Determine work content, and nature of equipment involved.

Day 1:

• Education in basic concepts
• Document current process
• Observe current process – time operations

Typical 3-Day Agenda (continued)

Day 2:

• Calculate Takt Time
• Develop work combination to balance process
• Design new layout
• Establish methods to support flow – plan for every part
• Establish performance expectations

Day 3:

• Implement new process
• Confirm performance of new process
• Develop follow-up plan

The actual number of days required will depend on the amount of work content for the product family that is the subject of the event, as well as the ease of movement of the equipment involved.

Typical Deliverables
Actual implementation of the new layout, if time permits. A proposed process layout or layouts, with recommendation(s) for locating the proposed process in the existing facility if physical movement is not possible during the event.

Projected benefits of the proposed process, per the performance measures used.  Demonstrated results are often possible during the event itself.

Detailed documentation on new process design (e.g. standard work combination sheets, plan for every process)

Actions List that can be used to follow-up on any ideas, issues, etc. that could not be addressed

Continuous Flow Manufacturing
One Day Workshop

           Participants will learn in depth Continuous Flow Manufacturing concepts.  These concepts can be applied to any area within the operation, even some non-production areas.  The concepts covered will include Takt Time, Standard Work, Work Combination and Line Balancing, Work Station Design, Layout Design, Plan for Every Part, and Flow Management techniques.

A simulation will be conducted to demonstrate the difference between “push” versus “pull” versus “continuous flow” concepts.  With use of the simulation, the participants will witness first hand the substantial impact of the application of continuous flow concepts.  Numerous photographed examples will be provided to enhance the learning experience.

The various “tools” used in the creation of continuous flow lines will also be used including Process Observation forms, Standard Work combination sheets, Capacity Analysis forms, Operator Balance Charts, and others.  These tools are invaluable when re-designing existing production lines based on continuous flow concepts.

Duration: One day

Who should attend:  anyone who works in a manufacturing or production, including managers.  Office personnel that support the production process can also benefit by attending this workshop.  The concepts can also be applied to non-production transactional processes often found in some office environments.  Therefore, people who work in such areas would also benefit.