Reveal your potential | Kaikaku approach

18 June 2014 - 16:45

Operational excellence approach consists of 4 basic building blocks. It can be summarized as project management, Lean & Kaizen, sharing the best practices, health and safety implementations. These building blocks means nothing without its culture is revealed; for this, participation of the top management, trainings, measurement, and rewarding are the most important tools. If you have the building blocks and the culture elements works well, you should be able to measure that the excellence is at which level; for this you need the assessment tool, so you can prove how much the excellence is visible at the site.



Lean approach is of course very important in the operational excellence journey. There are different implementation types used in this approach; one of them and the most important one in my opinion is the applications for 9 weeks; in other words, Kaikaku.


There are 4 main titles, concentrated on the implementation. Resource planning, process design, organizational structure and efficiency, and performance management. In order to realize the implementation experienced resource requirement is unavoidable. The resources here are divided into two: the lean experts managing the implementation and the change agents who provides the communication with the site during application and who will perform the plan after the implementation. If you don’t get support from outside, it is absolutely necessary that the lean experts who will manage the implementation are trained beforehand. The expectations from the employees who will conduct the change agent duties are:


Terms of reference: He/she should learn the lean concept both in the on-the-job trainings and in the training sessions. He/she should be able to continue the implementation based on the plan after Kaikaku. He/she should have an active role in the project team; ensure the communication and information flow with the employees.



Profile: He/she should be a team leader or have one up position, have a grasp on the operational processes, be successful in the change management, concentrate on the implementation, instead of analyzing, be respected by the collages, and be able to delegate the existing duties in the 12 months afterwards.


If support will be outsourced 2 weeks before the commencement of the implementation, information should be given to the consultant. Even if it will be applied with its own resources, a preparation process is required for starting without a problem, such as preparation, survey and data studies etc. A half day facility visit should be made, a short training should be given and the expectations should be transferred before the implementation.


As you can see below, Kaikaku approach consists of 3 phases. After each phase, a top level information sharing and evaluation meeting should be planned, it is preferred that the manager in charge makes presentations in these meetings in order that he/she embraces the work. In summary, it consists of the phases of determination of the current situation of the facility (diagnostic), establishing the application plans for the necessary improvements (design) and realizing them (implementation) and takes 9 weeks.



Diagnostic: The current situation of the operation system is evaluated; the cycle time measurements are completed; value map is established (MIFA), mathematical definition of the wastes is made (OPE). It consists of defining the root causes of the basic waste sources and collection of all operation, finance and HR data. The existing situation, the thought structure and abilities of the management structure are evaluated.


Design: This is the stage of designing the future condition operation system elements. It consists of establishing the ideal process map based on the lean principles on MIFA, development of improvement ideas, defining the potential, implementation of the performance management, and defining the new resource scheduling process. Again the design of the monitoring tools, 5S implementation, lean game, and planning tools are realized in this phase.


Implementation: Detailing and testing of the prioritized ideas, implementation of the ideas with high priority, preparation of the application plan, and preparation of the monitoring tool are performed in this phase. In addition to the implementation of the prioritized ideas, quick-win and Poka Yokes will be implemented in parallel during the implementation.


After the implementation of the prioritized ideas, the procedures should be standardized and developed for sustainability. Their performance should be monitored for the standards and the root causes of the lowness of the performance should be determined. It should be ensured that a system which will ensure that the best practices are shared should be established. By only this way, the sustainability can be talked about; at this point, the top management embracement and the effect of the change leader are unavoidable.


Regards, Kaner Pakis


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I love the Rock the Drop idea, and maybe I’ll do it next year if I remember! I’d totally be like you though. Even though I’m leaving something for free, I’d totally look guilty about it. Haha. I mean, it’s kind of like littering or something right? And in terms of something like that- like a free book, I’d be like, “Is this really free? Can I really take th?ya”Answiy, cool idea, and good job!