Lps10 lplans

8/13/2018

KAIZEN PLANS
GVC. ThS. Nguyễn Như Phong
; www.isem.edu.vn
Kỹ thuật Hệ thống Công nghiệp
ĐH BÁCH KHOA – ĐHQG TPHCM
(Tài liệu giảng dạy cho ISE)
2018

KAIZEN PLANS
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Create Kaizen plans
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

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VS Kaizen stages
Planning recap
Prepare for implementation

Implement Kaizen Plans
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


Recommendation 4 coping w. change
Keep the big picture in mind

Wrap up

11 April 2003

Nguyễn Như Phong

1


8/13/2018

Create Kaizen Plans
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Create detailed plan
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

guide efforts 2 improve the VS
wo. solid planning
 slim chances 4 successful lean transformation

11 April 2003

Nguyễn Như Phong

Create Kaizen Plans
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Schedule recurring meeting 2 ensure

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Communication flows
All involved parties remain on the same pace

VS project status
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In partnership w. VS champion
As milestone attained
Tools 4 highlighting concerns & potential solutions

11 April 2003

Nguyễn Như Phong

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Create Kaizen Plans
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Comprehensive planning


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very important
but plans
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not perfect
modified as

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proceed through implementation
gain more practical experience w. L manu methods

11 April 2003

Nguyễn Như Phong

VS Project status: June 30

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Schedule

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Accomplishments

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
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Target completion date of 30/12
Draft charter
Conducted training class on VSM
Modify PF 2 A & B only

11 April 2003

ThS Nguyễn Như Phong

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VS Project status: June 30

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Concerns (Issues)
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Ability 2 maintain meetings at 3pm
Utilize a more planning tool 2 schedule improvement

Plan
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Schedule meeting 4 1pm
Team leader 2 utilize KMW
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4 detailed implementation of DFL focused kaizens

11 April 2003

ThS Nguyễn Như Phong

VS Kaizen stages
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The monthly kaizen plan
Milestones:
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
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Break the plan into manageable pieces

Complete the VSM storyboard
Catchball

11 April 2003

Nguyễn Như Phong

4


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VS Kaizen stages
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To increase the chances of success,
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plan the implementation using the stages:
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Plan how 2 ensure 2 meet CD
Plan how 2 improve the process flow
Plan how 2 level production

Planning sequence

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most effectively & least costly
implementation of K plans

11 April 2003

Nguyễn Như Phong

VS Kaizen stages
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K planning process steps
1.

Review FSM
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2.

Determine milestones 4 each major K activity
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3.
4.

create a MKP
create KMC

Complete VSM storyboard
Obtain management approval
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11 April 2003

for KPs through catchball
Nguyễn Như Phong

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The monthly kaizen plan
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Plotting the implementation schedule
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Symbols 2 plot the timeframes
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for the main elements / events
accomplished in each stage of FSM
Open triangles – start dates
Dashed lines – expected duration
Closed triangles – completion dates

Macro-level sequence 4 implementation
MKP worksheet

11 April 2003

Nguyễn Như Phong

MKP worksheet
VS:

Date:
Schedule

Stage Event

11 April 2003

J

F

M

A

M

J

Nguyễn Như Phong

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Milestones:
Break the plan into manageable pieces

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Overall structure
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for the main improvement events in place
Create a series of specific milestones for each event

11 April 2003

Nguyễn Như Phong

Milestones:

Break the plan into manageable pieces
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Milestones
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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

11 April 2003

Nguyễn Như Phong

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Milestones:
Break the plan into manageable pieces
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Kaizen milestone chart – KMC

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Document & tract the completion of milestone
Show the sequence of
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implementation activities
completion over time

Get down 2 next level of detail
Monitor activities on an ongoing basis
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track progress toward completion

11 April 2003

Nguyễn Như Phong

Milestones:
Break the plan into manageable pieces
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Things not always go according 2 plan
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milestone achieved
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11 April 2003

earlier than planned
later than planned

Nguyễn Như Phong

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KMC
VS:

VS members:

Item

Task

Assìgn to

Date: 15/9

June
3

July

1

2

4

FGS

S

---

BS location

S

---

C

SS location

S

---

C

1

2

3

4

2

3

4

---

C

Demand

BS AMT

C

SS AMT

C

Ship Stage Area

C

11 April 2003

---

Nguyễn Như Phong

KMC
VS:

VS members:

Item

Task

Assìgn to

Date: 15/9

June
1

2

3

July
4

1

S

C

---

C

---

S

---

---

Flow
Machning supermarket
Line balance
Gravity racks
Kanban address

S
S

---

---

Restricted FIFO lane

S

---

C

Standardized work

C

S

---

---

C

---

S

---

Quick CO assembly
Pitch establish

S
S

Machining programming
11 April 2003

C

--C

Nguyễn Như Phong

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KMC

VS:

VS members:

Item

Task

Assìgn to

Date: 15/9

August

September

1

2

3

4

S

---

---

C

S

---

1

2

3

4

Leveling
Heijunka box
Runner route
Team Recognition

11 April 2003

C

All

C

Nguyễn Như Phong

Complete the VSM storyboard
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Time 2 complete the VSM storyboard
Add

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Proposed monthly Kaizen plan
Any other data overlooked earlier

11 April 2003

Nguyễn Như Phong

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PM CASE
Kaizen proposal
1st
Demand- Establish BSS, FGS, implement 5S

S

Flow – Cell design. Line balancing. Standardized work

S

Flow

– Reduce CO. implement AM

Level – establish runner route
Level – Implement Heijunka & kanban sys

2001
3rd 4th
C

2nd
C
S
S
S

C
C

Level – Additional TPM application: modify PM standards
Started - Complete - Past Due
11 April 2003

Nguyễn Như Phong

Catchball
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Time 2
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Presenting the plan 2 high-level managers

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play catchball
get buy-in 4 the plans
gain approval 4 the plan

Smooth Catchball process
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The FS planned carefully
Careful thought to
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11 April 2003

how the plan implemented systematically
Nguyễn Như Phong

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Catchball
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Prepare 4 the UM meeting

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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

11 April 2003

Nguyễn Như Phong

Planning recap
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Planning primarily about managing action
Guidelines 4 effective K planning
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Be realistic
Play catchball
Be detailed
Communicate
Make it visual
Recognize good work
Be sure 2 celebrate

11 April 2003

Nguyễn Như Phong

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Prepare for implementation
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Plan carefully – minor adjustment 2 the plans
Make whatever modification required




then prepare 4 the implementation

Various members of the implementation team
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lead a series of K events
make the changes necessary 2 transform the VS

11 April 2003

Nguyễn Như Phong

Prepare for implementation
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K events
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A team event
dedicated 2 quick implementation of L manu method
in a particular area
over a short time period

11 April 2003

Nguyễn Như Phong

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Prepare for implementation
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Main points of preparing K events
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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

11 April 2003

Nguyễn Như Phong

PM CASE

Implementation agenda
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VS: A&B
VS Stage: Demand
Event date: May 17-18
Kaizen event objective: Estabish a FGS sys

11 April 2003

Nguyễn Như Phong

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PM CASE
Implementation agenda

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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

11 April 2003

Nguyễn Như Phong

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

11 April 2003

Nguyễn Như Phong

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Prepare for implementation


Team recognition
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Transform a VS 2 its FS




may take a year or longer

People

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work long periods wo. feeling appreciated
bound 2 loose focus & enthusiasm

11 April 2003

Nguyễn Như Phong

Implement Kaizen Plans


Planning & preparation done

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

Proceed 2 the implementation phase
Enthusiasm & confidence

Kaizen activities



When implementation begins in earnest
impact on virtually everyone connected 2 the VS

11 April 2003

Nguyễn Như Phong

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Recommendation 4 coping w. change
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Change

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even 4 better
difficult 4 most people

The more people know about what going on
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the easier 2 deal w. anxieties
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11 April 2003

accompanying significant change

Nguyễn Như Phong

Recommendation 4 coping w. change
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Communicate
Address negative behavior early in the implementation

Not let the problem stop the process
Consider each kaizen event an experiment

11 April 2003

Nguyễn Như Phong

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Recommendation 4 coping w. change


Reward & recognize people’s efforts
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practice mutual trust & respect
treat people w. honesty & integrity every day

Be present
Be flexible

11 April 2003

Nguyễn Như Phong

Keep the big picture in mind

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Keep the big picture in mind as progress
Refer 2 the storyboard frequently



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2 explain 2 people how using VSM process

Fast, flexible process
Be patient & realistic

11 April 2003

Nguyễn Như Phong

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Wrap up


Continually to look for ways


to improve the entire VS

11 April 2003

Nguyễn Như Phong

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