We return to the flow in production issue, now regarding the need to introduce the second step in the KAIZEN™ methodology, which encompasses the application of standard work and low-cost automation.
Standard work is an approach focused on the observation and simplification of tasks, enabling the reduction of execution times through the measurement and improvement of the working methods used. Consequently, it is possible to align every
Following this logic, it is necessary, in the first instance, to define the desired improvement objectives, increasing team awareness towards their goals and increasing their focus on the results. The objectives selected should have SMART characteristics; in other words, be specific, measurable, achievable, relevant and time-bound, according to the requirements.
Implementing standard work involves closely observing employees executing the tasks that have been defined in the scope in the definition of the KPIs. This should not be performed via distance training, but through a conscious observation in the Gemba (the Japanese term meaning “the real place”). It is at this stage that the execution times must be
At a later stage, after collecting all the necessary information, potential solutions must be proposed; this is most effective when all employees have a good knowledge of the process. Common examples of implemented improvements are task elimination, initial sequence changes, machine adaptations, and concentration of materials needed in the added value area of the employee.
At this point, a need arises to test the solutions drawn and to verify their results, which, if positive, should generate the
The goal is always to
KAIZEN™ argues that processes always have a potential for improvement easily achieved through simple changes adapted to the reality of the
This application should only take place after all the previous steps have been followed through, which guarantees a process without waste. A common mistake in
In an increasingly competitive world, efficiency is a cross-cutting goal for any industry, company or work area. Observing, collecting data, and simplifying tasks in each process creates