Focused Improvement

Major Kaizen
Training Material

STRICTLY CONFIDENTIAL

WCM CENTRAL TEAM

Focused improvement
Major Kaizen
PDCA Approach:
Plan, Do, Check, Act
Under
Capire
stand il
problema
Problem

Identificare
Identify
leCauses
cause

Standardizzare
Standardize

Plan activity to study:

- Problem occurred;
- Identification of
problem causes;
- Identification and
prioritization of
solutions.

Act
Verify &le
Verificare
soluzioni
Monitore
monitorarle
Solutions

Check

Do: application of
solution.

Plan
Do

Apply le
Applicare
Solutions
soluzioni

Identify le
Identificare
soluzioni
Solutionse
dare
le priorit
priorit
& priorities

Verify le
Verificare
Causes
cause

Check: monitoring of
solution.
Act: standardization
of solution to similar
problems.
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Focused improvement
Major Kaizen
Kaizen: To analyse a problem and find a solution it is used a PDCA approach through the Kaizen tools.
They can be quick, standard, major and advanced.
Kaizen Choice
Choice of kaizen to use is
due to:
- Problem Complexity;
- Frequence of problem
occurrance (sporadic,
cronic);
- Time needed to solve
the problem;
- Number of people
involved in the team;
- Type of WCM tool used.

Focused improvement
Major Kaizen

Focused improvement
Major Kaizen

STARTING POINT: WHY

START A MAJOR?
Cost Deployment
Loss Deployment
C Matrix
QA Matrix
SA Matrix
TEAM DEFINITION
We need to define the
knowledge, skills and
abilities
ACTIVITY PLAN
Development of action plan

Focused improvement
Major Kaizen

PHENOMENA DESCRIPTION
5W + 1H: What, Where, Who,
When, Which, How

Countermeasures
Objective Definition

Use of Sketch

HOW THE PROCESS

SHOULD WORK

ANALYSIS OF CAUSES:
5WHYS, 4M
Sketch Use

Check Result

Standardization

Focused improvement
Major Kaizen

Focused improvement
Major Kaizen

STARTING POINT: WHY

START A MAJOR?
Cost Deployment
Loss Deployment
C Matrix
QA Matrix
SA Matrix

TEAM DEFINITION
We need to define the
knowledge, skills and
abilities

PLAN PHASE
- Objective: in this part it is
necessary to show the starting
point (QA Matrix, SA Matrix, C
Matrix). This information gives
the priority and reason why a
MK is needed.
- Team Definition team
members list with the
knowledge radar chart.
- Activity plan: definition of a
timetable where it is possible
show the scheduled activities.

ACTIVITY PLAN
Development of action plan

Focused improvement
Major Kaizen
PLAN PHASE
- Phenomena description uses
always 5W+1H tool, it is better
describe the problem with a
skecth.
PHENOMENA DESCRIPTION
5W + 1H: What, Where, Who,
When, Which, How

- System: in this part it is present

the description of how the system
should correctly work. This is
useful to understand the
difference between the correct
situation and the actual woth the
presence of the problem.

Use of Sketch

HOW THE PROCESS

SHOULD WORK

TARGETS
ANALYSIS OF CAUSES:
5WHYS, 4M
Sketch Use

- Causes: with this format it is

requested to describe the
analysis of the root cause (4M,
5Whys).
- Target: the definition is related to
the result to acheive.
Usually it is zero (zero breakdown,
scrap, etc.)
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Focused improvement
Major Kaizen

DO
Countermeasure: description of the
solution.
Skecth: better to use it, to show clearly
the countermeasure.
Put in this part all the analysis made to
obtain the solution.

CHECK
Monitoring and showing of results
comparing with the fixed target.

ACT
Consolidation and standardization of
solution to other cases if its possible.

Countermeasures

Check Result

Standardization

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