Improving Release Process to Avoid Supply Chain Bottlenecks
By implementing a Flow Management System, we tackled inefficiencies in a client’s batch release process, reducing lead time variability by 37% and enabling weekly releases to triple.
GOOD STORIES
A client sought support in developing a standardized approach for executing multiple Kaizen Blitz events within a year. The methodology was new to the company, and they needed guidance in both creating a structured framework and equipping local facilitators to sustain the initiative independently - without compromising results during the learning phase. To address this, we planned and facilitated the first Kaizen Blitz, collaborating with the local site to refine and finalize the approach. This tested framework would then serve as the foundation for the remaining planned events.
THE CHALLENGE
The client needed to complete 10 cross-functional improvement projects within a year in an already resource-constrained organization. However, they faced several obstacles: key stakeholders were stretched thin, many employees were new to the company, and shifting priorities due to a ramp-up phase made long-term planning difficult.
To overcome these challenges, they opted for the Kaizen Blitz approach – a methodology known for its simplicity and ability to quickly engage employees without requiring extensive training. However, executing multiple Kaizen Blitz events successfully required more than just individual workshops. The client needed a structured, repeatable framework that would:
Our role was to design and facilitate the first Kaizen Blitz event, using it as a pilot to refine the methodology. By the end of the project, the client would have a scalable standard that empowered them to execute the remaining events independently while maintaining high-impact results.
A Kaizen Blitz is an intensive, short-term improvement initiative – typically spanning 3-5 days – designed to drive rapid process enhancements. It fosters cross-functional collaboration, employee empowerment, and a sense of ownership over improvements, leading to sustained engagement and long-term impact.
For organizations with limited time and resources, this focused approach delivers quick wins without requiring prolonged commitment.
OUR APPROACH
The project focused on executing pre-identified improvement areas while ensuring alignment with the client’s maturity level and current operational state. Beyond delivering solutions, the approach emphasized creating a sustainable, continuous improvement process. This allowed for real-time learning, enhanced site maturity, and long-term process improvements.
A well-structured Kaizen Blitz begins with thorough planning. The success of these events depends on establishing a strong foundation for focused, high-impact decision-making. Our planning phase prioritized the following key elements, which ensured that the client was well-prepared to conduct future Kaizen Blitz events independently after the pilot.
Clear goals and KPIs guided the Kaizen Blitz, improving the “Right First Time” KPI by addressing deviation inefficiencies. A focused scope and early leadership alignment ensured impact.
Success relied on a cross-functional, engaged team with clearly defined roles. Employees needed clear mandates, while management remained available for swift decision-making and approvals.
With the right team in place, data was assessed, supplemented by interviews and additional collection efforts to support objective decision-making during the event.
THE RESULTS
By the end of the first Kaizen Blitz event, the client had a clear, structured approach for executing future improvement initiatives. The event not only delivered immediate process optimizations but also established a repeatable framework for continuous improvement.
Key outcomes included:
With this pilot event, the client was well-prepared to scale the approach across the remaining Kaizen Blitz events, ensuring consistent results while fostering a culture of ongoing improvement.
REACH OUT
Discover how a structured Kaizen Blitz framework can empower your teams to drive sustainable impact. Learnings from our recent pharma collaboration show what’s possible, even in complex, resource-constrained environments.
Reach out to Charlotte Gram Hartlev, Partner at our Improvement team, to learn more about building your foundation.
HAVE A QUESTION?
A Kaizen Blitz is a short-term, intensive improvement event typically lasting 3–5 days, designed to identify and implement process enhancements quickly. It involves cross-functional teams, focused problem-solving, and rapid decision-making, helping organizations achieve measurable improvements without extensive preparation or prolonged project timelines.
For pharmaceutical companies, a Kaizen Blitz streamlines processes, reduces waste, and accelerates operational efficiency. It enables quick wins in areas such as batch release, deviation management, and production flow, supporting compliance, reducing costs, and enhancing team engagement.
Team engagement ensures that those closest to the work contribute insights and take ownership of improvements. Engaged teams are more likely to sustain changes post-event, foster a continuous improvement culture, and drive long-term operational maturity.
Kaizen Blitz is more intensive and time-bound compared to traditional continuous improvement efforts. While continuous improvement is ongoing, Kaizen Blitz focuses on rapid results over a few days, making it ideal for addressing specific problems in resource-constrained environments.
Organizations can scale Kaizen Blitz events by developing a standardized framework, training local facilitators, and creating a repeatable methodology. This ensures consistency, maintains quality, and empowers local teams to execute improvement projects independently while achieving sustained results.
