| Successful workplace improvements are measured by the results achieved, as well as the length of time it takes to achieve these results. Significant reductions in business process cycle times, increased throughput, elimination of waste, and reduction in bottlenecks can be achieved rapidly. Actual results recent Kaizen Blitz workshops (Case Histories) by improvement category: |
| Space Reduction | 25 - 78% |
| Work-In-Process Inventory | 60 - 92% |
| Finished Goods Inventory | 13 - 67% |
| People Travel Distance | 33 - 78% |
| Tool Retrieval Distance | 25 - 74% |
| Parts Travel Distance | 25 - 92% |
| Lead Time | 38 - 99% |
| Non-Value Added Activities | 30 - 48% |
| Productivity | 15 - 25% |
| Change Over Time | 20 - 50% |
| Co. | Communications Company |
| Process: | FM Antenna Assembly |
| Goal: | To reduce floorspace, inventory and lead time by 50%. |
| RESULTS | REDUCTION ACHIEVED |
| Parts Travel Distance | 78% |
| Leadtime | 65% |
| Inventory | 66% |
| Space | 25% |
| Co. | Laboratory Equipment |
| Process: | Compressor Deck |
| Goal: | To redesign the deck to reduce the number of brackets by 50%, reduce copper by 25%, and reduce process time. |
| RESULTS | REDUCTION ACHIEVED |
| # Parts | 45% |
| Length of copper | 15% |
| Co. | Furniture Manufacturer |
| Process: | Office Panel |
| Goal: | Eliminate WIP, reduce lead by time, reduce floor space by 25%. Create 1 piece flow. |
| RESULTS | REDUCTION ACHIEVED |
| Leadtime | 97.8%(6 hrs. to 8 min.) |
| Inventory | 92% WIP |
| Space | 30% |
| Co. | Manufacturer |
| Process: | CNC Machine Center |
| Goal: | To reduce set-up time by time, reduce floor space by 50%, ensure first-part quality & clean, safe workplace. |
| RESULTS | REDUCTION ACHIEVED |
| Changeover time | 60% |
| Envir., Health & Less clutter, | better |
| Safety, 5S | lighting |