Get Everyone Trained in Kaizen

Achieve Massive Results

Use kaizen to continuously improve quality, cost, and delivery (QCD) on a massive scale. Teach associates not only to use lean tools, but to focus their efforts towards measurable and meaningful outcomes.

Align Your Efforts

Promote front-line lean enthusiasm that is smart, scientific, and that affects the bottom line. Tie together the three practices of 5S, waste elimination, and standardization into one holistic continuous improvement model: kaizen!

Create a Continuous Improvement Culture

No more "one step forward, two steps back." Gain traction with lean that endures for years to come by establishing a culture of continuous improvement

Kaizen Made Easy

We keep kaizen simple, and train concepts to unleash kaizen everywhere.

  • Bite-sized on-demand videos covering essential kaizen practices.

  • 20 training modules containing everything you need to know about kaizen (108 min).

  • Supplemental YouTube videos to reinforce concepts with real-life examples from a variety of industries.

Deliver Training on Your Terms

  • On the shop floor

    Play videos in daily stand up meetings. Reinforce lean behaviors for weeks and months to come!

  • In your next workshop

    Use the course as a complete kaizen curriculum in your next training class or workshop. Train management. Train associates. And even kick-off kaizen events.

  • At any computer

    Assign training to be completed at the learner's own workstation or desk. Any device with an internet connection will work (phones and tablets included)!

  • For each new hire

    Accelerate new hire comprehension with targeted lean training! Ensure that lean behaviors are taught for years to come.

  • In your next kaizen event

    Prepare participants in your next kaizen event with effective lean knowledge. Make sure they hit the ground running...and in the right direction!

Enroll in the Course

Available in the Lean Maniac and Enterprise Memberships.

What You'll Learn Inside the Course

  • The meaning of kaizen and the spirit of continuous improvement

  • The two functions of kaizen: maintenance and improvement

  • The role of standards, 5S, and waste elimination

  • The focus of quality, cost, and delivery in kaizen efforts

  • 7 cost-cutting kaizen activities to engage in

  • How to improve scientifically with PDCA

Course Curriculum

Section 1: Introduction

Video 1: What is Kaizen?

  • Discover that kaizen means small changes for the better, not big.
  • Learn the phrase, "everyone, everywhere, every day."
  • Find out where 80% of your potential improvement comes from.

Video 2: Kaizen Improves Standards

  • Find out what kaizen improves: standards!
  • Learn the two functions of kaizen: to maintain standards and to improve standards.
  • Realize that standardization is what sustains the gains of kaizen.
  • Understand the difference between physical and non-physical standards.

Video 3: Quality, Cost, & Delivery (QCD)

  • Learn to focus and align kaizen activities towards improved QCD
  • Realize that the customer wants the "highest quality at the lowest cost with the best delivery."
  • Understand how all three performance measures are interrelated.

Video 4: The Kaizen Trinity

  • Discover the three practices of the kaizen trinity: 5S, waste elimination, and standardization.
  • Learn how the kaizen trinity promotes continuous improvement.
  • Review each tool in brief and see examples.

Video 5: The Scientific Method

  • Stop improving haphazardly and learn to improve scientifically.
  • Discover the PDCA cycle (plan-do-check-act).
  • Realize how PDCA is disciplined and differs from DDDD.

Section 2: The Highest Quality

Video 1: Focus on the Process

  • Realize the difference between quality products and quality processes.
  • Learn that high quality processes result in high quality products.
  • Learn to end reliance on inspection by building quality in at the source.
  • Follow a funny example of making a cup of coffee.

Video 2: Poka Yoke

  • Learn the definition of a poka yoke.
  • Realize that a poka yoke prevents problems from occurring in the first place by eliminating the potential human error.
  • See examples of a poka yoke in everyday life.

Video 3: Don't Receive, Don't Make, Don't Ship

  • Discover what it means to "build quality in at the source" by developing in-station quality.
  • Learn to achieve quality from three perspectives: incoming, in-station, and outgoing.
  • Learn the priority of these three types of quality controls.
  • Understand that "the next process is the customer."

Section 3: The Lowest Cost

Video 1: Seven Cost Reducing Strategies

  • Realize that cutting cost matters and is essential to every organization.
  • Understand although there are "bad" ways to cut costs, these are not lean ways!
  • Learn the seven cost-cutting strategies to focus waste elimination efforts.

Video 2: Improve Quality

  • Realize that improving quality should be your #1 cost-reducing strategy.
  • Learn the concept of "cost of poor quality" and the many benefits of quality improvement.
  • Follow an example of poor quality in order to realize its financial impact.

Video 3: Improve Productivity

  • Define productivity in terms of output and input.
  • Learn what productivity is not.
  • Learn multiple productivity factors.
  • Understand how to best use people that are freed up due to productivity improvements.

Video 4: Reduce Inventory

  • Understand the many consequences of inventory to space, inventory management, lead time, quality, and cash.
  • Understand how inventory size affects material flow and cash flow.
  • Learn to find problems with flow by looking for inventory.

Video 5: Shorten the Production Line

  • Learn how the length of the production line affects QCD
  • Understand how transportation, multiple buildings, and the size of your value stream affects QCD.
  • Realize how work cell design and layout can allow for flexible manpower.

Video 6: Reduce Downtime

  • Understand how disruption to the production schedule is costly.
  • Learn how downtime promotes a mindset of over production.
  • Realize how downtime leads to premature capacity expansion.
  • Find out where to get downtime data.

Video 7: Reduce Space

  • Understand the value of space as a resource.
  • Understand the consequences of poor waste utilization in terms of efficiency and cost.
  • Learn five tips for reducing space.

Video 8: Reduce Lead Time

  • Learn how lead times affect inventory turnover, waste, and process feedback.
  • Discover the many benefits of a short lead time.
  • Appreciate a simple method for measuring lead time.

Section 4: The Fastest Delivery

Video 1: Fast Delivery

  • Realize that delivery matters to satisfy customers, win more business, and increase flexibility.
  • Understand the goal of a just in time (JIT) system.
  • Understand the role of lead time and production leveling in improving delivery performance.
  • Boost awareness for helpful lean tools.

Video 2: Short Lead Times

  • Learn how to define a lead time.
  • Understand how short lead times enable a faster response, faster recovery, and flexibility.
  • Learn how waste elimination, continuous flow, and batch sizes contribute to improved lead times.

Video 3: Leveled Production

  • Understand the value of production leveling in simple terms.
  • Learn two keys to effective production leveling: 1) good mixing, and 2) pattern production.
  • Witness a simple example of leveled production.

Section 5: The Scientific Method

Video 1: PDCA

  • Learn the four steps of PDCA: plan, do, check, and act.
  • Realize the use of PDCA for both big and small challenges.
  • Appreciate the value of small and rapid experimentation.
  • Witness a simple example of PDCA in application.

Video 2: FastCap Case Study

  • Witness 16 rounds of rapid PDCA in action while watching the external YouTube video "Kaizen FastCap Style."
  • See how small-scale experimentation can be leveraged to address big or complicated problems.

Enroll in the Course

Available in the Lean Maniac and Enterprise Memberships.