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Case Study - Reducing Cycle Time by over 50% via a 3-Day Kaizen Event


It took a large business on average 55 days to install a complex product.

1. We graphed the results, from data gathered during careful Kaizen-event preparation

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.

2. We identified apparent causes

Using a fishbone diagram, to highlight the key presenting causes.

3. We identified, and then solutionised, the root 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.

4. We implemented and measured

We adopted the solution and continued adding data to the Process Behaviour Chart established in Step 1., to ensure changes were effective, and sustained.

5. Result

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)!


Delivery to Plan


Cycle Time Reduction (days)


ROI from aorist consultancy, training and coaching

Businesses typically benefit from a 50 - 100+ times rate of return, when measuring the cost of an aorist Lean 6 Sigma or Systems Thinking / Systems Dynamics Simulation training course and coaching against the benefits derived from applying it the very first time in their business.