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Kaikaku, sometimes called Kakushin, is a Japanese Lean term meaning radical improvement in a limited time. It is a philosophy centered around creating more value and less waste in production by implementing major changes. Innovation is key to Kaikaku, and innovating new processes, new products, new management practices, and new machines can have a huge impact on the facility as a whole.
Kaikaku is often used in the context of another Japanese production philosophy, Kaizen. Both Kaizen and Kaikaku work to improve production processes but are two very different approaches. Where Kaizen is focused is focused on continuous incremental changes, Kaikaku works to make fundamental changes that will have a significant impact. Kaizen projects are typically smaller, require less resources, and project timelines are relatively short. On the other hand, Kaikaku changes are larger projects that require more resources, more staff, and a longer period of time to plan. Although more time, effort, and cost are put into Kaikaku efforts, changes will likely have a much more dramatic impact on efficiency and the bottom line.
A pilot test is used to ensure that an experiment, process, tool or method works. The pilot test can be done with a lot, batch or single piece with the objective of proving something new that has not been used before.
The check sheet is a structured data-recording tool. This generic tool is designed by users to facilitate, organize and track their interpretation of results. The check sheet is one of the seven basic quality tools.
When do you use it?
How do you use it?
The Ideal State is a reference to the absolute perfect condition. One way to envision the ideal state of a map, process, product or service is to imagine that money, time and resources were not limited at all. What would you create then? Ideal state value streams are created many times to show the gap between the current state and the ideal state. This can help teams to reaffirm they are in alignment and ensure that the progress made is on track.
The waste walk is one of the best ways to train employees, reveal waste and discover new improvement opportunities. Simply put, it is a time where teams or individual's head to the gemba and look for waste. The waste walk can be a standard activity, planned event or a now and then practice. The only skill people need to have during a waste walk is a basic understanding of the 8 forms of waste. The ©WASTES methodology is a problem solving methodology that is used by Lean Strategies International LLC. The methodology is a simple and easy to use 6 step method for conducting a waste walk or training/kata, . The six step process can be used with experienced employees who are seasoned in waste identification and it can be a great way to train new employees to develop a lean thinking mindset while learning to see opportunities to remove waste. The six steps involved in the ©WASTES Methodology are:
The Gemba is the actual place where transformation and value creation happen. The concept of the Gemba is applicable to any and all industries. Simply stated the Gemba is where the work is performed. Some examples of the Gemba are:
To learn more about the Gemba enroll in our ©GEMBA Methodology Course today.
**Share with us where your Gemba is in the comments section below**
The easiest way to define overprocessing is doing more to a product than what the customer, specification or transformative process requires the first time through. Overprocessing is sometimes referred to as inappropriate processing because it includes steps that are not needed, extra handling, duplication of activities and processes that are just not statistically capable of producing the desired results.
What types of overprocessing do you see on a daily basis?
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Overproduction is one of the 8 major forms of waste. It occurs when parts, services or information are created in excess of the needed demand or when services, products or information are created/delivered in advance of the needed schedule. To learn more about Overproduction click on the link below and enroll in our 8 forms of waste course.
Topics for discussion:
Overproduction is considered to be the deadliest waste of all forms of waste. Why in your opinion is this form of waste so "deadly?"
A backlog is every customer order that has been received as an order that has not yet fulfilled the customers request.
Transportation waste is any unnecessary movement of people, products, materials or information.