Our services are customer-focused and results-driven. We help prioritize your issues and invest our energy in opportunities to ensure return on investment and sustainable impact. In addition, we transfer knowledge and skills through well-developed training programs to achieve sustainable gains long after we have achieved the consulting objectives.
An overview of our service categories is listed below:
As partners, we help you create the essential components to drive your success. We assist in the identification, development, and implementation of new programs to keep your business protected and employees safe, engaged and injury-free. Program management is vital to understand program objectives, stay on track and validate results.
A review of operations and activities is critical to determine which jobs are candidates for improvement. We spend thousands of hours annually listening to your team and watching operations to develop the proper strategic and tactical next steps. Risk assessment is a critically important first step to identify exposures that may have an adverse effect on worker safety, process efficiency and product quality
Using data obtained during Risk Assessment, we develop practical solutions by combining our industry experience with detailed analysis and assurance with regulatory compliance. Improvement recommendations are supported by critical dimensions, illustrations, and vendor information to ensure a smooth path to implementation. Combined with our implementation service partners, we can work with your facilities team to bid, contract, prototype, and install equipment.
When you need immediate impact and payback, our Kaizen Event can be the first, best step towards improvement. A Kaizen Event is a highly focused, results-oriented workshop in which a team takes immediate action to improve work processes through simple, impactful and sustainable improvements. At the end of several days, your business will have begun a transformation to control common workplace safety exposures and to deliver immediate business value.
We have a reputation for great training programs that are customized to your needs. Our high-impact training programs provide information, knowledge, tools and hands-on practice to create and internalize your risk management effort.
Web applications provide the ability to leverage your impact. RMG offers several web applications to manage your ergonomics program, share best practices, and track kaizen event outcomes.
Kaizen Event Benefits
While many methods are used to implement Lean, one of the most popular is a Kaizen Event. These events are focused workshops to identify and implement low cost, high impact improvements. Using several principles of 5S, Lean, and Ergonomics, a Kaizen Event combines training, analysis, and real-time changes using employee teams to deliver immediate business value and employee safety.
The Kaizen Philosophy
Kaizen, an integral part of the Lean Production philosophy, is a Japanese word that means “good change.” It makes employees jobs easier by studying them and making little improvements. The intent is to make jobs safer and more efficient by improving the working environment. The focus is immediate action rather than longer-term alternatives.
Improvement begins with the belief that every organization has opportunities for change and improvement. Traditional wisdom holds that “If it isn’t broke, don’t fix it.” However, the Kaizen philosophy takes the view that every process can be improved and therefore even if you think it isn’t broken, fix it anyway
The Kaizen Event
The best knowledge resides with the operators who actually perform the work. They know the problems and often the solutions. During a Kaizen Event, small teams of operators and maintenance employees make the recommendations on how to improve processes and then make the physical changes to the processes. These teams support and continue the process after the event is over.
Because operators know the process, work the process, and are involved in the change process, there is tremendous buy-in and ownership of all improvements. Changes created through the Kaizen Event are very sustainable. The processes rarely revert back to the less safe and less efficient way of doing things.
One of the key concepts of a Kaizen Event is that “If there is No Action, there can be No Success.” The goal is not a 100% solution that solves all the problems at one time, but rather a 70% solution that can be accomplished in a few days with the intent to hold another event in several months that further improves the processes. The improvement does not have to be perfect the first time, but the process should be better today than it was the day before. During Kaizen Events, employees strive for “base hits,” not “home runs”. Everyone should be looking for ways to make change happen.
Quick, simple, and low-cost is better than slow, complicated, and expensive. Employees should utilize what exists in the facility (and forgotten storage areas) or off the shelf purchases to implement a new improvement quickly.
A Kaizen Event is not a license to spend. The essence of a Kaizen Event is making improvements with what you have – use existing tools, machines, materials, space, etc. Overall emphasis is placed on creating solutions and improvements with existing assets. As a result, Kaizen Events are a very cost-effective method to create dramatic improvements in processes.
Kaizen Event Training and Rollout
A typical Kaizen Event is Three to four days long, comprised of a cross-functional team usually with 12 to 15 employees. The team is composed of people who are in the process to be reviewed, such as the lead operators and supervisors. Additional resources from other departments such as maintenance and safety are assigned to support the event. Even personnel from local vendors/suppliers can be included.
The process is simple, but needs significant coordination. Training is completed the first morning in the classroom. In the afternoon, the tools that were taught are applied on the shop floor, with more emphasis on issue identification. Reports are made several times each day to the group and other teams to exchange ideas, keep teams posted on progress, resolve issues, and seek additional resources. Teams are empowered to identify and improve their work areas..
The scope of the Kaizen Event is to be able to complete the changes and have the new and improved process up and running by the last day. Improvements are measured for impact and verified to ensure additional issues are not created. Improvements are generally summarized in a PowerPoint presentation and shared with the other teams and management on the last day. Communication plans are discussed and executed, so when operators come in on the next shift, the new processes are in place. People understand the improvements made, and why and how to safely operate equipment and tools within the new process.
A Kaizen Event is a simple, effective, and powerful approach to drive accelerated workplace changes that improve productivity and workplace safety. Conducting Kaizen Events on a one-time or regular basis is shown to increase efficiencies of a team or organization and identify low-cost changes that result in high-impact improvements.