What is a Kaizen Blitz?

The Kaizen Blitz is a system implemented by those looking to create a lean manufacturing technique to reduce waste, impact safety and hazard reductions, and increase productivity. Kaizen is a rapidly and widely implemented improvement system that is meant to be long term. By definition, Kaizen means "improvement" or "continuous improvement." Kaizen Blitz implementation is small but constant in nature. Although a Kaizen Blitz is discussed by a relatively small group of individuals in a short amount of time, the operational changes it makes are dramatic.

A Kaizen Blitz can be used to resolve a small but nagging long-term problem or it can be used to completely redesign a procedure. It is a small improvement that brings about a drastic change. In other words, many things done a little better consistently can dramatically improve output.

Below is a Kaizen Blitz event held at one of our WCTI member facilities. Take a look!

 

Kaizen Blitz Event Continues on at Peerless Industries!
Peerless Industries in Melrose Park, IL, was one site for a WCTI Kaizen Blitz event. But it didn’t stop there with Peerless Industries. Participants from the Kaizen event and other employees have continued to improve production efforts while reducing risks of musculoskeletal disorders (MSDs).
	Employees work on the new line configuration at Peerless Industries.
	Early in the Kaizen event it became evident that there was extra material handling of the product during the process. Employees spent a lot of time walking back and forth while carrying product to the various work areas. Now the lines and staged product are much better organized so the workflow is more streamlined. With less manual transfer of product, employees’ risk of sustaining an MSD injury is also reduced. When the Kaizen event was over, there was only one mock workstation set-up. Now the entire area has been reorganized so that many more employees benefit from the changes.
The packing area has been moved much closer to the product paint line, reducing production time and potential injury from carrying products.
Many of the lines allow the worker to be more upright (heights and reaches of product and equipment were modified). This is important in reducing potential back and shoulder injuries. Management has also examined different methods for folding boxes and coached employees in these improved methods. But Peerless is not resting on its laurels; management still has plans to improve the process, which includes development of a custom training program for employees in this work area. Employees at Peerless Industries really know what it means to do “continuous improvement.”
	This computer stand was made so that each employee could easily adjust the equipment to his or her own height.
These custom stands to hold bubble wrap (left) and to hold miscellaneous packaging items (right) have been made in-house. Employees are now able to place materials at arms' reach. This has helped employees reduce bending, stretching, reaching, and twisting upon packaging a product.