On-Site Lean Kaizen Event Facilitation
“6Sigma.us” team of Lean Experts and Master Black Belts have provided event facilitation globally for over 10 years with clients in all business segments and industries.
We realize that each event is unique and may be very focused or very broad in scope, which will vary the length of the event. It also requires different preparation, change management, data collection and facilitation needs. The key to a successful event is the preparation and planning before the event using a cross-functional team. Included in this price is coaching and mentoring prior to the event, using the phone, email & virtual meetings (GoToMeeting).
Having an outside perspective, someone who is independent of your processes and business can be a huge advantage to using an external consultant. We aren’t biased by what has been done in the past, and we can bring our experience from multiple companies and industries to assist the team. We realize it can take a lot of effort to plan an event, and we can walk you through those steps, so that your kaizen event gets completed, and gets the impact you desired. You don’t have to research what to do next or hope that you did everything correctly. We will coach and mentor you so that you can run your own events in the future (by providing a co-facilitator that we can work with).
Ensuring successful Lean Kaizen Events
Prior to the Kaizen Event, we will help you with the following tasks to ensure a successful event:
- Define the business case (why kaizen event is important)
- Determine leadership sponsors and champions
- Agreed upon deliverables and scope
- Determine the duration of an event (between 1 – 5 days)
- Identify team members and co-facilitator (someone at your company)
- Develop an agenda
- Define the preparation work and data collection needed before the kaizen event
Please contact us to discuss the scope and deliverables of your kaizen event, so we can help you determine the duration and estimated cost.
Full Assistance Provided
During the kaizen event, we will assist with the following activities:
- Facilitate the discussion per the agenda
- Mentor and develop co-facilitator
- Consult with the leadership and co-facilitator from your company on adjustments to make during the event
- Organize daily report outs for management and sponsors
- Help develop a final report out and action plan
- Provide recommended next steps for co-facilitator to follow-up after the event
Popular Lean Kaizen Event Types
Process Mapping Event
Duration: (1-3 days)
Ideal for understanding the current state, ideal state and future state of a process. Not as complex or as expansive as a Value Stream Map (informal mapping with less data collection and preparation). Ideal for mapping processes within a department or small team.
Value Stream Mapping (VSM) Event
Duration: (3-5 days)
Ideal for mapping the flow of material or information from customer request to customer delivery, spanning multiple departments and organizations. A great approach when you are just starting out, so you can decide which areas should be worked on first. Requires considerable preparation work to gather data for each major process step prior to the event. During the event, training is provided, go and see (gemba walk) is conducted, then Current State VSM is created. Wastes and opportunities are identified on the map, and an Ideal state map is developed. A future state map (6-12 months in the future) is developed, based on the gaps from Ideal State and Current State. End result is a Future State VSM, with a list of opportunities with assignees and due dates for improvement, in order to move the process closer to the Future State.
Kaizen Burst Event
Duration: (3-5 days)
A working session, where the purpose is to complete a specific set of tasks by the end of the event. There is a limited amount of analysis, most of the time is spent implementing the changes, and validating that they work. These are ideal for bringing a team together to make significant progress on a task that has been dragging on too long. Unlike a mapping event, 80% of the actions are completed during the event, with the remaining 20% completed within the next 30 days.
Duration: (3-5 days)
Interested in getting immediate results and benefits in an area or department, without having to learn a bunch of Lean terminology or tools? 5S events are a great way to get work spaces organized and decluttered, and the results are immediate, which builds excitement from the team to take on future improvements. This goes beyond “spring cleaning,” as we walk your team through the 5 steps (5S) for organization. At the end of the event, the team will be through the Sweep, and will have some standardization in place, along with a draft of the sustainment plan.
- Sort – Remove items that aren’t needed often from the area
- Straighten – Organize the remaining items based on frequency of use, make it easy to find and put away
- Sweep – Clean the area, so you have a good starting point
- Standardize – Develop consistent labeling, signage, terminology, and rules to follow
- Sustain – Maintain the improvements over time
Total Productive Maintenance (TPM) Event
Duration: (3-5 days)
Ideal for getting your process equipment back to ideal working condition, and setting up processes to maintain it, so there is less risk for downtime. We start by identifying the key equipment or area to focus. Next, we break down and inspect the entire machine, and get it back to “optimal working condition.” Data systems are put in place to determine when equipment isn’t working properly, and the top drivers of downtime are investigated and continuously improved. Finally, preventative maintenance is implemented to reduce degradation of the equipment.
Standard Work Event
Duration: (5 days)
This is a type of kaizen burst event, but specific to the implementation of standard work on a process. Ideally performed after a VSM event, the team gathers to review the process, conduct a gemba walk, and review the preparation work collected prior to the event. The team goes through a series of steps, including: Calculating takt time, creating workload balance sheet, completing standard work combination sheets to separate value added from non value added tasks, performing level loading of work across the stations, defining work sequence, calculating standard Work In Process (WIP), redesigning the space to optimize flow and reduce waste, implementing the layout change, and validating that the new processes and layouts are working properly.
6Sigma.us is offering the following options for Lean event facilitation and consulting support:
- 1 day – $3000
- 3 days – $8000
- 5 days – $12,500
On-site support during the preparation stage is also available at the same rates.
For example, if you would like a 5-day VSM event, and 2 days of on-site preparation support, the cost would be $10,000 for the event, $5000 for the preparation work, plus travel expenses for both trips.
Reschedules and cancellations should be made at least one week in advance and may require repayment of lost or extra travel expenses.