Our Methodology
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Diagnostic
A comprehensive assessment to identify gaps and opportunities for improvement.
Improvement
Rapid process enhancement through our Focused Improvement (FI) Workshops.
Standardization
Implementation of robust practices to ensure sustainable improvements.
Sustainability
Ongoing support and frameworks to maintain and build upon progress.
OUR APPROACH
The Kanzen Journey
Perfection is not attainable However if we chase Perfection We can achieve Excellence ~ Vince Lombardi (Add This as a slider)
KANZEN is the Japanese word for “PERFECTION”, an ideal but dynamic state which has no specific definition. Every time we think we have reached this state, we find that something more can be improved and the bar is lifted just that little bit higher. The KANZEN journey entails this quest for perfection in the three key components of People, Process and Technology and the interplay between them.
By embarking on this journey, our clients not only gain tangible business benefits but also develop a unique culture that makes continual improvement a Way of Life. Lean principles form the cornerstone of the journey and each process and activity is viewed under the lens of value addition versus waste. The KANZEN journey is typically marked by four main phases,.
Current State Assessment: We first understand the business goals for the next 3 years from the top management. This is followed by assessment of the current state vis a vis the organization goals to identify the gaps to be bridged. A roadmap is then prepared to close these gaps – listing improvement areas, specific projects and timeline for implementation. A core team of champions is also identified to work closely with our consultants through the journey.
Improvement: Identified constraints and bottlenecks are eliminated or minimized as radical process improvements are done in a relatively short span of time through our unique Focused Improvement Workshop approach. People are trained on concepts of Flow and Pull and to use tools and techniques such as One piece flow, SMED, SPC, Kanban etc. Significant results can be seen during this phase itself.
Standardization Phase : Most gains and improvements are short lived as the operational processes are not robust enough to keep them going. In this phase, we look to involve each and every person in the organization through 5 S, Total Productive Maintenance (TPM) and Daily Works Management (DWM). The activities become part of the daily routine and helps develop ownership for the workplace, machine and process.
Sustenance Phase :. We believe that the role of the consultant ends with putting in place a self-sustaining framework so that organization is firmly set on the path of Continual Improvement. A calendar for process audits and 5S assessments is prepared, KRAs / KPIs of individuals are aligned to continual improvement goals and a rewards and recognition mechanism put in place. The core team who have been working closely with KIAP team now take over and drive the initiative in the long term.
Rapid implementation through Focused Improvement Workshop
In our unique Focused Improvement Workshop, within a short span of 3-5 days, the process gets redefined most often leading to dramatic improvements and gains. This is made possible by bringing together all the relevant people in the form of cross functional teams – each team will work on and complete at least one significant improvement project during the workshop. The concerned process owner leads the team thereby ensuring long term sustenance of the improvements made during the workshop.
Our Methodology
KIAP’s methodology has two core elements – rapid process improvement through Focused Improvement (FI) workshops and assessment based handholding for sustenance post the improvement phase.
In our unique Focused Improvement Workshop, within a short span of 3-5 days, the process gets redefined most often leading to dramatic improvements and gains. This is made possible by bringing together all the relevant people in the form of cross functional teams – each team will work on and complete at least one significant improvement project during the workshop. The concerned process owner leads the team thereby ensuring long term sustenance of the improvements made during the workshop.
Assessment is a key part of the sustenance phase. KIAP has developed customized checklists based on globally accepted operations excellence framework . The assessment measures overall process performance in terms of a measurable score and lays down the basis for further improvement. Cross functional teams then work on improvement projects, under guidance of KIAP experts, to improve the scores. This becomes a template for the organization as it moves into self sustenance on the continual improvement path.
