Kaizen Event Planning

A kaizen event (also called a rapid improvement event or RIE) is a concentrated, cross-functional effort to improve a specific process in 3–5 days. Unlike a long-term project, a kaizen event changes the process immediately during the event week.

Pre-work (2–4 weeks before)

Define scope: one focused area, measurable goal (e.g., "reduce changeover time from 45 min to 15 min")
Collect baseline data: current state metrics, process map, photos
Select team: 5–8 people including operators, engineering, and a fresh-eyes observer
Schedule: reserve the area, arrange coverage for team members' normal duties
Order materials: label makers, tape, shelving, any tools likely needed

Event week structure

Day	Activity
Day 1	Training, current-state walkthrough, data validation, target setting
Day 2–3	Brainstorm, design improvements, begin implementation
Day 4	Complete implementation, test the new process, measure results
Day 5	Standardize (update procedures, train operators), present results to management

30-60-90 day follow-up

Assign a sustaining owner. Verify metrics at 30, 60, and 90 days. Unresolved items from the event ("parking lot" items) must have owners and due dates — not just good intentions.

CQE exam tips

Kaizen events focus on waste elimination using lean tools; Six Sigma projects focus on variation reduction using statistical tools.
The team must include the people who actually do the work — management-only kaizens rarely stick.

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