Kaizen Training Skillnet is a network of manufacturing companies working to implement Kaizen continuous improvement tools and techniques, and build in-company Lean expertise.

The network is made up of 10 core companies who are undergoing a Lean transformation programme over a two year period, and a wider network of 20 companies who are collaborating and learning from the project. The companies in the project are as follows:

Trend Technologies - Mullingar, Co. Westmeath
Tool and Plastic Industries - Longford
Harmac Medical Devices - Castlerea, Co. Rosscommon
Allergan Pharmceuticals, Westport, Co. Mayo
Valois Ireland, Ballinasloe, Co. Galway
Athlone Extrusions, Athlone, Co. Westmeath
Mergon International, Castlepollard, Co. Westmeath
Moffett Engineering, Dundalk, Co. Louth
Hasbro, Waterford City
Bose Ireland, Carrickmacross, Co. Monaghan
ANSAmed, Boyle, Co. Rosscommon
TRUpour, Longford
JFC, Tuam, Co. Galway
Sennheiser, Tullamore, Co. Offaly
Killarney Plastics, Killarney, Co. Kerry

Kaizen and Continuous Improvement
Kaizen, (kai – zen) - Japanese words that literally translates to good change, which in the west is known as Continuous Improvement. The principle of Kaizen is to empower many people to make relatively small, but good, or positive changes within their own area of expertise. This is in contrast with major changes conducted by third parties, or relatively small numbers of individuals who are often detached from the process.

Implementing a culture of Kaizen or Continuous Improvement is a holistic process that requires the commitment and support of management and the active participation of the entire workforce.

Individuals need to understand and be accountable for the key performance metrics attributable to their specific area of the business. These local metrics should be aligned with corporate goals and contribute towards overall organisational success.

Typical metrics whilst being process specific, will be defined within the overall banner of Productivity, Quality, Cost, Delivery, Safety and Morale (PQCDSM).

The next phase of Kaizen implementation is to train staff in Improvement Techniques such that they can make continual positive changes to their own areas of responsibility. A significant part of this process is the empowerment of the work force, enabling them to implement positive change to their process, within established organisational guidelines.

The overall objective is to establish a culture where the business is divided into autonomous areas of excellence with their own metrics and Kaizen improvement programme, all contributing to overall organisational goals and success.

Typical Kaizen tools and improvement techniques will include:

Process Measurement & Analysis
Visual Management Systems
The Deming Wheel of Improvement - Plan, Do, Check, Act
Waste Elimination
Zero Defects
TQC. Total Quality Control
TPM. Total Productive Maintenance
SMED. Single Minute Exchange of Die
Kanban & Just in Time
Line/Process Balancing
Poka Yoke
Team Building & Working
Problem Solving
Standard Operations

Improvements gained are maintained through the use of Standard Operations. Standard Operations ensures that the method deployed in order to carry out a particular task is consistently carried out in the best, possible way currently available to the individuals with a vested interest in the process.

Kaizen Training Skillnet is funded by member companies, the European Social Fund and the National Development Plan

Bill Stacey pictured below, from Hasbro in Waterford, helping the project participants understand the true value of Value Stream Mapping