Kaizen process

Course Objectives
Enable structured continuous improvement activities within any process.
Build team work and esprit de corps within an organization.
Improve efficiency, productivity, and quality within any operation.
Provide a structured methodology that reduces cost and increases profitability.
Course Description
The Kaizen Facilitator Course teaches the skills required to successfully lead a team to conduct
continuous improvement activities within their working environment. Tools from Lean and Six Sigma
are taught that support the Kaizen Improvement Process. The process follows the Deming
Continuous Improvement Cycle of Study the Process, Determine Corrective Actions, Plan and
Prioritize the Actions, and Implement the Improvements. This course shows how to quickly make
sustainable improvements.
You are first introduced to Gemba Kaizen, continuous improvement in the workplace, and then each
of the Kaizen Improvement Process steps are covered in detail. Tools and templates are provided in
either MS Office or OpenOffice.org productivity suites. This course provides 20 hours of continuing
education. Upon completion of the Final Course Exam you will be issued a Course Completion
Certificate.
Completion of this Course and one Kaizen Improvement Project makes you eligible for the Kaizen
Facilitator Certification from the Management Development Institute of Missouri State
University. Master Black Belt Support is available at help@educatevirtually.com
Course Contents
Kaizen Facilitator Introduction
Contents Overview
Kaizen Facilitator Toolkit
Gemba Kaizen Introduction
Seven Wastes
Housekeeping 5S
Standardization
Kaizen Improvement Process
Gemba Kaizen Exam
1. Study the Process
Study the Process Introduction
Team Work Skills
Team Work in Meetings
Leading Teams
Team Failure Top 10 List
Process Mapping
Value Stream Mapping
Deployment Process Mapping
Voice of the Customer
Data Collection
Data Collection Video
M&M Data Review
Exercise MTB Data
Exercise MTB Pareto
Measurement System Analysis
MSA for Attributes
Exercise MSA MTB Attributes
MSA for Variables (Gage R&R)
Exercise MSA MTB Variables
Exercise MSA MTB Rubber Bands
Nature of Variation
Histograms
Exercise MTB Histogram
Individual Measurements Chart
Exercise MTB IM Chart
Pareto Analysis
Exercise MTB Pareto Analysis
Study the Process Exam
2. Determine Corrective Actions
Determine Corrective Actions Introduction
Value Added Analysis
Pull System Illustrated
Process Activity Analysis
Kanban Calculator Use
Kanbans in Action
Affinity Diagrams
Cause and Effect
Failure Mode and Effects Analysis (FMEA)
Exercise FMEA Template
Hypothesis Tests
Movie p Value Explained
Analysis of Variance
Movie F Stat and p Value
Exercise ANOVA in MTB
Movie Making a Helicopter
Exercise ANOVA Movie
Developing Creative Solutions
Movie SCAMPER Brainstorming
Movie Edison Brainstorming
Movie Idea Box Brainstorming
Movie Brutethink Brainstorming
Determine Corrective Actions Exam
3. Plan and Prioritize Actions
Plan and Prioritize Actions Introduction
Build the Future State Process Map
Gap Analysis from Current State to Future State
Define Ongoing Controls
Standardization and Documentation
Exercise Standards Movie
Exercise Standards in MTB
Evaluate and Select Solutions
Exercise Priority Matrices
Plan the Implementation
Plan and Prioritize Actions Exam
4. Implement the Improvements
Implement the Improvements Introduction
Visual Management System
Implement the Plan
Kaizen Facilitator Final Exam