Day 1 went well.
The team consisted of ; Mfg Mgr, 2 Group leaders, 1 line associate, 1 engineering, Q.C. Manager, and 1 maintenance person.
The event sheet was kept simple describing the team, current situation, goals, scope, and required resources. (Just a reminder, this was set up as a kaizen event, not a blitz).
On day 1 we spent 7 hours in a class presentation covering the specific tools and concepts required to do a well planned Kaizen. This covered teamwork, quality tools, and brainstorming, kaizen priority, kaizen tools, etc.
The purpose of this introduction was to provide information to the team about what is expected to be understood and completed in a Kaizen event. Also, to allow an easy training format for new members before they are allowed to participate in a Kaizen event. By doing this, we do not isolate new members by over whelming them with activities using concepts they have not previously heard of before.
On Day 2, we began construction of a standardized work combination table. I chose to do this instead of the standardized work chart because the process under study takes about 6 hours. As a result, the std work chart would have looked like a spaghetti diagram. (On day 3, we will break this process down into 3 or 4 sections and make 3 or 4 std work charts.) We were able to finish about 85% of the standardized work combo chart and will complete this today. We will then spend about 4 hours on the line making time studies of the critical or key process, complete the std work comb table, and std work chart before analyzing points of Kaizen. (It has already become apparent that the people working in this cell are only working 70% of the time they are recording as actual work, so by implementing standard work, we should gain a minimum of a 20% provided we reduce the manpower associated with this activity).