It took a large business on average 55 days to install a complex product.
On a Process Behaviour Chart, to understand if the problem was systemic. The way the problem manifests (systemically or not) determines the most efficient and effective improvement approach to adopt.
Using a fishbone diagram, to highlight the key presenting causes.
Using 5 Why's Analysis, to find the real root causes. By correlating them to the problem to ensure proven causality, when we solutionised we were confident of success.
We adopted the solution and continued adding data to the Process Behaviour Chart established in Step 1., to ensure changes were effective, and sustained.
Time to install was reduced to 27 days on average, a 50% reduction, achieved in just 3 days Kaizen analysis and solutionising (plus additional pre-Kaizen event preparation time, and post-Kaizen event implementation time, of course)!
