Building a Scalable Kaizen Blitz Framework
Discover how we build a scalable Kaizen Blitz Framework starting with a pilot event to refine the framework for future implementations.
GOOD STORIES
Delays in the approval and release processes can create significant bottlenecks in the supply chain, jeopardizing a company's ability to meet demand. We recently helped a client overcome such challenges by implementing a Flow Management System. Here, we tackled inefficiencies in their batch release process, ultimately reducing lead time variability by 37% and enabling weekly releases to triple. This scalable solution, now being digitized for broader application, empowered our client to exceed weekly targets and restore operational predictability.
THE CHALLENGE
The client reached out because the approval of deviations and batch release for external manufacturers had become a bottleneck in their supply chain. They were unable to meet their weekly targets and, without intervention, could not see how they would catch up to their yearly target.
Unable to meet demand and unaware of the root cause, management felt that their unpredictable performance was affecting their trustworthiness and leverage, both internally and with their manufacturers.
For the project to be successful, the objectives were to:
OUR APPROACH
We approached the problem using our Observe-Think-Improve methodology to ensure any solution targeted the right problem.
OBSERVE
Verification of Core Process Activity
Prior to our arrival, a process mapping workshop had been held. To reduce re-work, we decided to verify the mapping with users to add enriching details like timeframes, document flows, and IT systems. This also helped us identify necessary and wasteful process variations. The review uncovered several systemic issues:
Analysis of Current Process Performance
The process verification provided insight into the IT landscape, enabling the creation of a dataset to analyze past process performance. Key findings included:
Assessment of Supporting Processes
The analysis showed that control mechanisms, such as securing deviation reports were handled and ensuring early notifications, could greatly stabilize release times. However, coordination meetings revealed that processes were more reactive than proactive. Every week, the batches were hand-carried for release, which often delayed other tasks. Key observations were:
THINK
Problem definition
Due to a lack of overview of activities and effort required before the expected week of release, the organization spends its effort clarifying the status of activities, assigning tasks, and escalating issues for a batch during the same week. This limits their performance as they can focus their efforts only on one to two prioritized batches.
Hypothesis
Implementing a takt system with the activities and relative effort required prior to release would enable the organization to
IMPROVE
To test this hypothesis, the team developed a minimally viable solution to quickly implement and adapt the tool. They used a standard takt time to align with current performance, focusing on three key elements during implementation:
After implementation, weekly releases increased. Continuous improvements were made based on user feedback, with the tool being maintained and enhanced by the users themselves. The organization embraced the tool, often exceeding weekly targets by up to 70%, a performance previously unseen.
As the solution proved effective, we moved to digitalization. Wireframes, user stories, and requirements were created, and we advised the business on software options. Once a supplier was selected, we supported the development and implementation of the digital tool.
Within six months, we achieved the following results:
KEEN TO LEARN MORE?
If this story felt familiar, you’re not alone. We helped this client cut lead time variability by 37% and triple their weekly releases—without overloading the team.
If you’re facing similar bottlenecks, contact Jakob G. Thorup, Partner at Emendo Improvement, to explore how we can help restore predictability to your release flow.
HAVE A QUESTION
A flow management system organizes and monitors the sequence and timing of tasks required to move products through processes such as batch release, production, or distribution. It helps streamline workflows, improve predictability, and reduce bottlenecks by visualizing task dependencies and prioritizing work in progress.
Bottlenecks in product release can lead to delayed shipments, unmet customer demand, increased operational costs, and reduced overall supply chain efficiency. Addressing these bottlenecks is essential for maintaining reliable production schedules and meeting yearly output targets.
Typical causes include:
A takt-based flow management system breaks down workflows into standardized time units (takt time), enabling teams to align tasks, anticipate issues, and proactively manage workloads. This approach reduces late escalations, clarifies priorities, and minimizes lead time variability.
Digitalization provides real-time visibility, automates task tracking, integrates data from multiple systems, and improves scalability. It helps maintain consistency across departments and locations while reducing reliance on manual processes or paper-based methods.
