Lean Kaizen Tools
Kaizen Event Planning templates (sometimes spelled "kaizan, "kaisan", or "kaisen")
Similar, familiar tools
to organize your teams
in diverse, appropriate ways
Download kaizen tools to get...
- A dozen templates that you will use for Kaizen Event leadership
with no expiration date
(use them free — for the rest of your career)
- A dozen templates that your teams will use for process improvement
with a 60-day trial period
(to get a glimpse of how much better your tools could be)
to plan your next Lean Kaizen Event
Microsoft Office templates for Kaizen Event Planning and Leadership
Kaizen Event Planning
Follow the instructions for how to launch any team for continuous improvement.
Notice that you get most of those event planning templates as free shareware.
You will get the Kaizen Team Roles, Kaizen Agenda, and many others when you own your license.
Kaizen Event Checklist
When the big wigs travel in from out of town
to participate you continuous improvement event,
and that spotlight shines bright and hot on your face,
you're going to truly appreciate having a field-proven Kaizen Event Checklist
to thoroughly prepare to get the best results from your team's intensive time spent together.
Your Kaizen Checklist will help you avoid embarrassing and costly oversights
as you prepare to launch your kaizen team.
Kaizen Agenda template
After getting your Team Charter approved…
begin fleshing out the details of your Kaizen Agenda.
Email your Kaizen Agenda along with your Team Charter to every person identified on the Communication Plan sheet in your Kaizen Planning Checklist.
Use your Agenda to stay on track
to complete everything that needs to be done during your Kaizen Event.
The Event Coordinator should bring it to the Facilitator's attention if the group falls significantly behind schedule.
Kaizen Event Leadership
Planning is good. Successful execution is even better.
Caution: If you have never led a Kaizen Event, don't do it alone.
You should co-lead several events under the mentorship of an experienced leader
before stepping into the spotlight to serve as the primary leader or facilitator.
Depending on the purpose and scope of your Team Charter,
you could use any number of process improvement tools.
Tip: Use your Tool Selection Matrix
In every continuous improvement event, you will always use both of your Kaizen PowerPoint templates:
- The Event Training PowerPoint
to cannibalize slides to mix with your own favorite slides
to teach THIS team the essentials they need to know
- The Event Presentation of Results
to quickly prepare your daily report-out presentations
to you present to your executives and stakeholders
at the end of each day of your event
Kaizen Continuous Improvement
Your goal is to complete as much as possible during your 1-5 day event.
You will almost never reach that ideal.
Event Action List
Kaizen Newspaper Action List
Use your Event Action List template (eventAction.xlsx)
to collect issues and ideas that arise
before, during, and in the days immediately following an Event,
and to assign responsibilities and deadlines to finish up all loose ends
in the days immediately following an Event
Some Event Leaders prefer to use the To Do List template
Both of these templates come with your free trial
Potential Future Improvements Ideas Parking Lot
Ideas Parking Lot
Step 1) Decide who will author this document
There might be one document author —
or you might designate your entire Continuous Improvement Steering Team as the author, and store this in a folder with write permissions for all possible shared document authors.
Step 2) Collect ideas for potential improvements
Every Continuous Improvement Team Leader should be trained to collect ideas for potential improvements, and ensure that all ideas are recorded here.
Step 3) Periodically review and prioritize ideas
and make plans for upcoming Improvement Events.
Tip: This is a good time to return (again) to your Hansei questions to stimulate Lean Thinking.
And much more
Unlike a hodge podge of non-standardized templates collected from perhaps forgotten consultants, and "free" Internet downloads, and templates created from employees that eventually move on (and now who's going to support them?)...
Once you learn how to find help and training for any Systems2win template,
you know how to find help and training for every Systems2win template.
Your Systems2win templates empower your leaders
with an entire suite of templates to measure results (and get results)
Download a dozen free kaizen tools that you can use for the rest of your career — free
because our gamble is that once you become familiar
with your Systems2win templates that have
- consistent, standardized features, help, and training
- language translations for your global team
- live technical support
you will wonder aloud...
"Why are we paying our expensive lean leaders
to try to invent, re-invent, and support inferior tools?"
Kaizen Videos & Training
Additional relevant training
The Sample and Help worksheets of every template
Bookmark = why
The Kaizen Method — why do it?
The Kaizen method is quite simply the fastest, most field-proven way to:
- Achieve rapid and sustainable improvements
- Shine an intense burst of improvement on a process
- Truly involve everyone that has a stake in the process
- Hold process stakeholders accountable for measurable improvements
- Improve both profitability and employee morale at the same time
- Do it again and again; each time squeezing more juice, more value, and happier people
Bookmark = Event
What is a Kaizen Event?
An intensive burst of business process improvement
1) Preparation by the Event Leaders
2) Anywhere from a half day to a 5-day Kaizen Event
where representatives from every group of stakeholders devote undivided attention to improving
one business process with clearly defined boundaries.
Examples of clearly-defined improvement objectives might include:
- Reduce costs by 20%
- Reduce process cycle time by 50%
- Reduce scrap by 80%
(Little 5% improvements are usually not worth the attention of a kaizen event. You are looking for BIG improvements!)
3) The day after your Lean Kaizen Event
- When the new process is expected to actually be used!
- There are usually a few loose ends to clean up
Nine principles for
Lean Kaizen Continuous Improvement
"Perfection is not attainable, but if we chase perfection we can catch excellence."
~ Vince Lombardi
Bookmark = first
Your First Kaizen Event
Criteria for selecting your first few processes to improve
Training to get you started.
Tools you won't outgrow.
Suggested focus for first Kaizen Events
- Setup time reduction
- Standardized work for productivity improvement.
Processes that increase output, or reduce resource requirements.
The ideal process for a first kaizen event...
- Is guaranteed to succeed
- Enjoys the enthusiasm of everyone involved — especially middle management
- Is a bottleneck that will break open dramatic increased productivity for the entire value stream
- Has obvious potential for dramatic improvement
- Is an easy project — a confidence builder
- Is pretty much a self-contained process that isn't influenced greatly by outside forces
- Involves a physical product (rather than information or management policy issues that can be kaizened later)
- Doesn't require computer programming or any technology that can't be completed in 3 days
- Doesn't contain a "monument" that can't easily and inexpensively be replaced in 3 days
- Won't require exceptional involvement of outside support (e.g. riggers, maintenance, IT...)
- Won't cost very much money
- Ideally involves a product that can be made with a cell with fewer than a dozen operators
- Ideally involves a product with medium to high volume
- Is a stable, repeatable process that isn't plagued with equipment downtime or yield issues
- Has clearly defined and easily understood performance measures
- Is a simple process that is well-known and/or easily understood by everyone
- Can be copied and used in other areas
- Is highly visible
Exception: if top management isn't fully on board yet,
then sometimes a 'stealth kaizen' can be the best way to prove the concept
Bookmark = Reading
Suggested Reading and Resources for
Kaizen Tools and Event Planning
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