GASA – Continuous Productivity Improvement

Standardized Kaizen Project Plan

(Version 1.1)

By: adidas Group Continuous Improvement team

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 Lean Measurement System Apparel

Based on CI Objective Apparel 2009 Tier 1/2

Establish a standard program to benchmark and measure factory lean performance

Measurable: Number of factories with Kaizen project plan implemented:

Deliverable Approach Lead/milestones

Project brief Define Project plan

Team
CI / April 09
Document Project plan CI/ June 09

Scope

Phases Introduce CI / June 09

Targets Roll out Sourcing/CM/ June 09

Timelines Measure CI/ Dec 09 ( incl. in aLF audit )

Status updates

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 Lean Measurement System Apparel

GASA – Continuous Productivity Improvement

Standardized Kaizen Project Plan

Deliverable Contents
Project brief Kaizen Project Brief

Team SOP for Kaizen Project Brief

Scope Kaizen Project Brief Example

Phases
Kaizen Method Information pack

Targets

Timelines

Status updates

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Kaizen Project Brief
(1) KP-09-xxx
(2) Kaizen Project Name: (2) Date: YYYY-MM-DD
(3) Kaizen Project Leader: (4) Start: YYYY-MM-DD (4) Finish: YYYY-MM-DD

(5) Team members:

(6) Problem Statement : Department: Process:

(7) Target Setting :

(8) . (A) Root Causes , (B) Quick Action, (C) Improvement:

(A).
(B).
(C).

(9 )Benefit to Business: Quality Productivity Delivery Cost Saving Safety Morale

(10 ) VOC:

(11) Before Kaizen: Process (or) Picture (or) Graph/Chart (11) After Kaizen: Process (or) Picture (or) Graph/Chart

(12) Baseline (Current) Before Kaizen (12) Result After kaizen: LEAN Measurable Improvement

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SOP for Kaizen Project Brief
1. Insert the Kaizen Project Number.
2. Insert the Kaizen Project Name and date.
3. Insert the name of the Kaizen Project Leader.
4. Insert project start date & finish date.
5. Insert the names of the Kaizen team members.
6. Write the problem statement, department and process.
7. Insert target setting
8. Explain the Root causes, Quick action (explain your action plans to improve the
problems) and Improvement (show measurable results)
9. Tick the item of how this kaizen will benefit the business.
10. Write "VOC (Voice of the Customer)"~ customer's requirements (if any)
11. Add the before and after Kaizen processes (or) pictures (or) graphs/charts for a visual
comparison.
12. Include baseline data before Kaizen and the LEAN measurable improvement after
Kaizen.

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 Kaizen Project Brief Example
(1) KP-09-001
(2)Kaizen Project Name: Improve efficiency in sewing cell # 3 (2) Date: 2009-06-10

(3)Kaizen Project Leader: Stanley Mao (4)Start: 2009-05-15 (4)Finish: 2009-06-02

(5)Team members: Vincent Li, Stone Shi, Toliver Chang

(6)Problem Statement : Department: Production floor A Process: Sewing cell #3

The efficiency in this sewing cell is lower than others in average of 20% based on April's production output report.

(7)Target setting : Improve PPH from 0.22 to 0.30

(8)(1).Root Causes, (2). Quick Action, (3).Improvement:
(1). Cell set up was based on supervisor's personal experience with no supportive data.
(2). Use Line Balancing technique to measure cycle time of each operation and establish Takt time.
(3). Improve PPH from 0.22 to 0.41

(9) Benefit to Business: Quality Productivity Delivery Cost Saving Safety Morale
Less overtime, efficiency improved, higher EOLR, estimate of financial saving USD$5,000/month
(10) VOC: Customer expects to increase the overall output of the cell in next 2 months.

(11)Before Kaizen: Process (or) Picture (or) Graph/Chart (11)After Kaizen: Process (or) Picture (or) Graph/Chart

748 CT/TT Chart 1

800 691
646
605
600
558 524 545 500 443 437 445 445 448 450 448 431 464 461 435 447 442
475
466.3 450 419 402 404 405 423
392
400 342 305 354 400
297.1
233 218.4 350
153 172 300
200
250
0 200
A B C D E F G H I J K L M N O P Q R 150
Cycle Time 233342 305297466218 392691748 354153172646 558524545605 475 100
50
Takt Time 570570 570570570570 570570570 570570570570 570570570570 570
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Cycle Time Takt Time

(12)Baseline (Current) Before Kaizen (12)Result After kaizen: LEAN KPIs Improvement

EOLR was 5 pieces/hour (Wadded jacket) EOLR was 9.2 pieces/hour