Rapid cycle improvement projects or kaizen events are built around the simple DMAIC five-step model. Toll gates are established between each step. The purpose of the toll gate is to give the team an opportunity to review progress before moving on to the next step. Please refer to a previous article for move information on toll gates. The five steps are:
- Define: What’s the problem? Every kaizen event starts with a project kickoff and a selection of team members. The team defines the problem by listening to the voice of the customer. The team engages in a gemba walk to identify critical measurements, and the scope is narrowed to focus on the actual problem. A project charter is developed and approved by the LEAN Committee (LC).
- Measure: Do we have data? What is that data telling us about the problem? If we don’t have data, do we need to collect data and how we go about collecting that data?
- Analyze: What does the analysis of the data tell us? Do we really understand what the problem is? Have we pinpointed the root cause of the problem or are we just trying to eliminate the symptoms of the problem?
- Improve: What are the possible solutions to the problem? We need to determine which is the best solution. We need to define the roles and responsibilities for the development and implementation of the solution. A project plan for implementation including any training must be developed. A pilot needs to be set up so that we know the solution is effective. Finally, the solution is rolled out across the organization.
- Control: How we are going to sustain performance? A control plan and a response plan are developed. Handover and acceptance by the process owner occurs once this plan is in place.
- Unofficial but important: Celebrate!