A Kaizen Blitz is a very intensive and focused approach to Process Improvement.  A specific set-up process is selected for analysis by a multi-functional team of people.  The team analyzes a specific set-up process by use of videotape.  The videotape provides an objective means for the team members to “step out of the process”, and see it more clearly.  The Set-up Reduction team will define each step of the process, as well as time each step.

Thereafter, the team will challenge the current process and identify opportunities for improvement.  A review of Set-up Reduction concepts and techniques is integrated throughout the exercise.  These concepts include, but are not limited to: external vs. internal activities; component and tool reduction; quick changeover fasteners; teaming concepts; point of use storage of materials.  A new set-up process is designed, and its performance projected.

Whenever possible, elements of the new process are implemented during the Kaizen Blitz, and the results verified.  However, more typically, additional time is required to implement the various improvements identified.  Changes to equipment, tools, fixtures, etc. all take time, and some expense.  Therefore, confirmation of the results is usually performed at some point in time in the future, typically within 30-60 days.

A three day Kaizen event is conducted in the production area on a particular set-up process.  A team of internal personnel is identified, and is facilitated through a six step approach to implement Set-up Reduction concepts.  Education in Set-up Reduction concepts is integrated throughout the event.  The Set-up Reduction Kaizen will result in; a documented set-up procedure; projected performance of the new set-up process; a videotape of the old and new set-up process that can be used for training purposes; an implementation plan and actions list.  A 50% – 95% reduction in set-up time is typical.

Typical 3-Day Agenda

Pre-event:

• Scoping: identify subject of the event, determine current set-up time

Day 1:

• Education in basic concepts
• Observe and Videotape actual set-up process
• Analyze process, identify process steps and times
• Identify external vs. internal activities

Day 2:

• Design new set-up process and project performance
• Develop Implementation Plan
• Initiate changes

Typical 3-day Agenda (continued)

Day 3:

• Complete changes
• Re-run set-up, verify results
• Develop follow-up plan

The duration of the event will vary based on the current time to set-up or changeover.  For example, it will require more time to document, analyze and re-design a 6 hour changeover process than a 2 hour process.  The actual changes possible to implement during the event will depend on the nature of the changes.  For example, some may require physical changes to the equipment or tooling that is just not possible during the event itself.  Such items will be included in the follow-up plan.

Typical Deliverables

•  A cross functional team of people who will understand QCO concepts and the methodology used to implement them, and who will be experienced in their actual application.
• A proposed and documented set-up process, with supporting analysis.
• Projected benefits of the proposed process, per the performance measures used.  These benefits will be verified by the end of the event whenever possible.
• Actions List and implementation plan to assist in follow-up, if physical changes were not possible during the Kaizen event.

Quick Changeover
One Day Workshop 

            One of the greatest impediments to flow is the need to changeover equipment from one part or product to another.  Lengthy changeovers are one of the key drivers for large batch sizes, which in turn increase the amount of inventory a company must carry.  Still further, quality defects, scrap or wasted material is often another outcome of lengthy changeovers.  However, many companies have still not applied the common sense concepts of quick changeover or what has also been called “Single Minute Exchange of Die (SMED)”.  Therefore, they are reluctant to challenge their historic big batch processing ways.

This workshop will review the six-step methodology that is used to reduce changeover or set-up time.  This methodology typically makes use of video taping and other documentation techniques that allow for a thorough analysis of the current process.  Video taping techniques will be covered as will specific QCO concepts.  These include how to measure true changeover or set-up time, distinguishing between “internal” and “external” activities, methods to convert internal to external, streamlining techniques, and teaming approaches.

The workshop makes use of a simulation to enhance the learning experience.  The participants will be able to apply most of what they have learned to the simulated changeover process.  Numerous photographed examples from a wide assortment of industries will also be provided.

Interestingly, quick changeover techniques have been applied to non-production processes such as the month-end closing process found in many companies.

Duration: One day

Who should attend: anyone involved in the changeover of production equipment can benefit by attending this workshop including operators, set-up technicians, material handling, quality personnel, scheduling, supervisors and managers.  Even non-production personnel can benefit by this workshop as changeovers of various types exist in the office environment.