Kaizen Sketchbook: Description and Table of Contents       cover  

What is Kaizen?   Kaizen merges work and process improvement without increasing chaos because diverse teams of contributors, including direct operators, follow a strict discipline to design a precise choreography of people, equipment, materials and information flow that is devoid of waste. The improved flow achieves delightful success and is sustained through consistent leadership and visual controls.

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The Kaizen Sketchbook explains and illustrates Kaizen in hundreds of pages of color illustrations, charts, demonstrations and step-by-step examples. It is a walking slide show of best practices and idea catalysts. Including an extensive glossary, index and very selective timeline, this portable guide will inspire, instruct, and support consistent application of Plan, Do, Check and Act Kaizen.

 

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The author, Marypat Cooper, has compiled over 20 years of process improvement experience into the Kaizen Sketchbook, including her notes from multiple sessions with Dr. W. Edwards Deming as well as over 14 years under instruction by students of Taiichi Ohno. She has combined the technical features of kaizen with the social aspects, including numerous office applications together with production floor examples to give the reader timeless value.time Study

 

The book includes hundreds of specific examples of how to observe, try-storm, prioritize and implement ideas for improvement. Step-by-step instructions for prioritizing issues, taking time study and resolving team conflict are organized, accessible and portable.

 

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Value Stream Maps and Strategy Deployment are extensively explained and fully drawn in color.

 

A forward by Gary Brooks and introduction by Jim Cutler, a timeline of the history of lean development and a glossary of over 250 terms give the owner a broad yet useful perspective.

Table of Contents

Forward by Gary Brooks, CEO of Esselte

7

Introduction by Jim Cutler, President of Moffitt Associates

11

How to PLAN Kaizen

Kaizen Topic Selection

23

Affinity Process with Inter-Relationship Diagraph

28

Value Stream Analysis

33

Simple Value Stream Map Icons 

37

Strategy Deployment

53

Communicate the Kaizen Topic Selection

65

Kaizen Team Selection

59

Team Roles and Responsibilities

67

 Ground Rules

74

Essential Forms and Supply Checklists

77

How to DO Kaizen

Kickoff

86

Observe Safety

87

Observe the 5 S

85

Direct Observation of Work through Space

103

Direct Observation of Work in Terms of Time (Construction of Standard Work Forms)

113

Useful Data and Sigma Tools

133

Find the Best Idea

145

Idea Catalysts

159

Implement the Best Idea

166

Specific Examples of Kaizen

169

To Build a "House Without Waste"

171

Kaizen for a Better Work Area Flow

172

Office Kaizen

178

Setup Reduction Kaizen

186

Kaizen for Better Internal Material Flow

192

How to CHECK Kaizen

How the Staff Checks on the Kaizen Team: the Daily Leaders' Meeting

198

How the Team Leader Checks Kaizen Progress Hourly

201

How a Facilitator Checks and Intervenes as Needed

203

From Plan to Do to Check to ACT!

213

The Final Presentation

217

How to ACT Kaizen

Regular and Productive Attention to Standard Work

219

On Leadership

228

Perspectives

A Very Selective Timeline

233

Lean Enterprise Assessment

237

Recommended Reading

241

Sample Curricula for Standard Training Modules

243

Glossary

245

Index

281

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