Kaizen Event Fieldbook: Foundation, Framework, and Standard Work for Effective Events

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9780872638631: Kaizen Event Fieldbook: Foundation, Framework, and Standard Work for Effective Events
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Foreword by Arthur Byrne

Awarded the prestigious Shingo Research and Professional Publication Award in 2010!

Kaizen event effectiveness is a prerequisite for lean transformation success. It provides the necessary transformational jump-start, momentum, organizational learning and engagement, and sustainable, step-function improvements. The systemic use of kaizen events establishes the technical and cultural foundation for principle-driven kaizen--the powerful combination of kaizen events and daily kaizen activities. The Kaizen Event Fieldbook brings this all together as an indispensable reference for lean leaders and implementers within any industry and for use at any stage within the lean implementation journey.

One of lean's defining characteristics is learning by seeing, doing, and studying. In context with lean theory and lean leadership principles, readers will gain an understanding of the essential 'whys' and 'hows' of kaizen event standard work and event management, as well as a proven means to sustain the gains. The Fieldbook's multi-phase approach addresses strategy, pre-event planning, execution, and follow-through. Practical examples, over a hundred figures and tables, and many real-life Gemba Tales provide for an enriched learning experience. Also included is a chapter on the deployment of a kaizen promotion office, a glossary, and two appendices, which offer blank forms and an overview of daily kaizen.

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About the Author:

Mark R. Hamel is a lean six-sigma implementation consultant. He has played a transformative role in lean implementations across a broad range of industries including aerospace and defense, automotive, building products, business services, chemical, durable goods, electronics, insurance, healthcare, and transportation services. A successful lean coach to leaders and associates, he has facilitated hundreds of kaizen events and conducted numerous training sessions and workshops.

Mark's 19-year pre-consulting career encompassed executive and senior positions within operations, strategic planning, business development, and finance. His lean education and experience began in the early 1990s when he conceptualized and helped launch what resulted in a Shingo award-winning effort at the Ensign-Bickford Company. Mark holds a BS in Mathematics from Trinity College in Hartford, Conn., a MS in Professional Accounting from the University of Hartford, and a MA in Theology from Holy Apostles College and Seminary. He is a CPA in the state of Connecticut and is dual APICS: The Association for Operations Management certified in production and inventory management (CPIM) and integrated resource management (CIRM). A national Shingo Prize examiner, Mark assisted in the development of the Society of Manufacturing Engineers/Association for Manufacturing Excellence/Shingo Lean Certification exam questions. He is also Juran certified as a six -sigma black belt and a member of the Society of Manufacturing Engineers, Association for Manufacturing Excellence, and APICS: The Association for Operations Management.

Review:

A critical distinction from other texts on the market, the Fieldbook links the technical aspects of kaizen to lean philosophy. Kaizen is the game changer in any lean transformation, and this is the game book.--Bruce Hamilton, President, Greater Boston Manufacturing Partnership

The Fieldbook is a must read for those wanting to understand the kaizen methodology. Mark Hamel clearly identifies its role utilizing the TPS version of SDCA and PDCA. He further traces his follow-through model to the 'learn-by-doing' methodology of the Training Within Industry (TWI) program, which was developed in the U.S. during WWII, and is going through a resurgence today as companies struggle to sustain kaizen gains. This book now has a prominent place on my bookshelf.--Robert J. Wrona, Executive Director, TWI Institute(R)

Applicable to any industry, the Fieldbook shows you what kaizen looks like when done properly. I plan to give one to each of my CEO clients.--Linford Stiles, Chairman and CEO, Stiles Associates

The Fieldbook is a roadmap for organizations to follow as they actively seek a continuous improvement culture and positive bottom-line performance. It is an essential reference for the proper application and implementation of kaizen. I intend to provide everyone on my management team with a copy.--Max Willsie, Plant Manager, Toyota Boshoku Canada, Inc.

Lean is about results and outcomes, not just intense focus on the process. The Kaizen Event Fieldbook balances theory with the tactical nuts and bolts, providing a practical roadmap for managers at all levels to strategically deploy kaizen and bring positive results to the bottom line.--Ted Gramer, Executive Vice President and General Claims Manager, Liberty Mutual Group

An exceptional and in-depth review of the technical components of kaizen, I found this book to offer sound guidance on how to avoid the pitfalls of inadequate preparation, uncommitted leadership, and lack of focus on sustaining the improvements in business performance that lean anticipates. It is a true reference that I anticipate returning to again and again.--Jack M. Dutzar, M.D., President & CEO, Fallon Clinic, Inc.

Amazingly prescriptive and reflecting years of knowledge acquired from renowned sensei, Mark Hamel has done a masterful job with the Fieldbook. Managers, instructors, and employees in any lean or aspiring lean company, within any industry, will find it an indispensable reference to impact positive, sustainable change. I plan to use it as a teaching tool for employees throughout my organization.--David A. Amrhein, Vice President, Operations and Lean Enterprise, Ascent Healthcare Solutions, Inc.

--***

During any lean implementation, the pace of kaizen events is critical to maintaining momentum. This well organized, readable book will help us standardize and refine our approach.--Kenneth Chandler, Vice President of Operations, Smith & Wesson

Engaging your entire workforce in driving business results is fundamental to lean success. Mark Hamel has done an outstanding job of laying out the team kaizen methodology. The Fieldbook is a practical guide and I recommend it as a read for every business leader and lean practitioner.--Jerome D. Hamilton, Global Director, Lean Six Sigma & Business Initiatives, 3M --Richard Levesque, Vice President and General Manager, Professional Division, MAAX U.S. Corporation

During any lean implementation, the pace of kaizen events is critical to maintaining momentum. This well organized, readable book will help us standardize and refine our approach.--Kenneth Chandler, Vice President of Operations, Smith & Wesson

Engaging your entire workforce in driving business results is fundamental to lean success. Mark Hamel has done an outstanding job of laying out the team kaizen methodology. The Fieldbook is a practical guide and I recommend it as a read for every business leader and lean practitioner.--Jerome D. Hamilton, Global Director, Lean Six Sigma & Business Initiatives, 3M Industrial & Transportation Business

In the Kaizen Event Fieldbook Mark Hamel reveals the tricks of the trade for leading effective kaizen events. More than just the technical tools, he emphasizes the importance of understanding and mastering the emotional element to influence and engage employees at every level, which is critical to creating a lean culture.--Julie DeWane, VP Global Supply Chain, GE Security

Individuals and organizations looking to either get started or improve their kaizen capabilities will appreciate the hands-on, step-by-step approach provided in the Fieldbook. A guide for success, it also warns of the pitfalls to watch out for on the course of the journey. I am definitely ordering this book for my entire team and selected leaders, and would recommend it to anyone serious about lean.--Stephen R. Malick, VP, WW Business Improvement, Johnson & Johnson Vision Care, Inc.

--***

Executing effective kaizens is always a challenge. I have not seen any other book on the market that gets into this level of understanding kaizen events--from pre-planning to follow-through. This book will benefit not only the new adopters of lean, but also the early adopters who require a 'back-to-basic' understanding of how to properly execute kaizen events to effectively drive change. ----Richard Levesque, Vice President and General Manager, Professional Division, MAAX U.S. Corporation

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