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Description

Project that will use data included. I have also attached an example of this project that may be used as a guide for mine. EXAMPLE can be used but info needs to be changed to MY PERSONAL INFO that is included in my projects. Assignment details below:

1.Improvement Project (Kaizen Event) – This kaizen event or improvement project does not need to address all issues found in Assignment 2, but students are expected to coordinate and implement at least one kaizen or improvement to this process to tackle some of issues analyzed in Assignment 2. Follow this template to document this mini-kaizen event (

Improvement Project (Kaizen Event) Template

). This template includes some example entries to help students understand how to use it, as well as state a kaizen objective, ideal conditions, brainstorming potential actions (apply the lessons to this project), and prepare an implementation plan for this mini-kaizen event. Students should follow the steps on this template and edit the entries to support their own improvement project using this template (the action items from the course lessons provide further information to support this assignment).

·Students will develop a master improvement plan in Assignment 4 for additional improvements (beyond the scope of this class). While brainstorming improvement alternatives now some options may not fit this time period, but be good considerations for Assignment 4.

2.Review Impact – Students need to plan enough time to complete this kaizen event or improvement project in order to have time to measure the impact the improvement(s) had on the 3 process measures defined in Assignment 1. These 3 future metrics or measures should clearly show the impact these changes or improvements had on the performance of this process. Students need to structure 3 impact statements supporting these measures (see example on the template).

3. Identify Lessons Learned – Include challenges and experiences while doing this assignment. Generalize what you learned for use in later process improvement projects.

Submit Assignment 3 on Sunday at end of Week 6 by 11:30 PM (EST). This submission should use the template provided (if students need to change the format to fit the organization, you are free to use a different format as long as similar steps as on the template are included).

Please watch video for info –

assignment 3 r1 – YouTube

I will include my project 1 and 2 so you will know what info to use in the attached example.

MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
Mourning Routine – Perfecting Breakfast: Improvement Project (Kaizen Event)
Student:________________
St. Petersburg College MAN4584
Date: ____/_____/____
1
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
2
Table of Contents
Table of Contents ……………………………………………………………………………………………………………. 2
Process Definition …………………………………………………………………………………………………………… 3
Metrics ………………………………………………………………………………………………………………………….. 3
Waste Audit with Process Owners …………………………………………………………………………………….. 3
Reasons for Kaizen …………………………………………………………………………………………………………. 5
Desired Conditions………………………………………………………………………………………………………….. 5
Potential Actions for Improvement ……………………………………………………………………………………. 5
First Actions …………………………………………………………………………………………………………………… 8
Performance Measure After Implementation………………………………………………………………………. 8
Lessons Learned……………………………………………………………………………………………………………… 9
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
3
Process Definition
The process within our morning routine that was chosen to focus the improvement
process on is perfecting breakfast. The process includes prepping, cooking, serving, and cleaning
the breakfast process. It will not involve obtaining raw materials, cooking tools, utensils, serving
plates, or cleaning supplies. This continuous improvement effort will eliminate the waste within
the current state process, eliminate variation, and standardize work for the breakfast process.
Metrics
The measurements of the breakfast process will be measured using three different
metrics. The metrics used will be time, task completed (either pass or fail), and an acceptable
result within specifications (temperature and doneness).
Waste Audit with Process Owners
In the initial waste audit, I found two significant areas of opportunity to improve. The
first was the breakfast process, and the second was the coffee process. Both processes are equally
important and set the tone for the day. The breakfast process in the initial waste audit revealed
that there was a considerable amount of waste. Below are the items observed during this phase of
the process improvement and updated from the original waste audit, explicitly focusing on the
breakfast process.
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
4
Morning Routine Process
Typical Waste
Categories
Describe Issues Identified
Process Owner
Overproduction
• Made too much breakfast for two
people
• Husband
Excess Inventory
• Excess breakfast raw ingredients
• Husband
Waiting or Idle Time
• Waiting for the cooktop to heat up
• Waiting for the toast to finish
toasting
• Husband
Non-Value-Added
Processing
• Cracking eggs
• Husband
Defects, Mistakes,
Rework, Corrections,
Queries, Inspect Others
• Eggs overcooked
• Toast burnt
• Avocado not ripe or too ripe.
• Husband
Excess Motions
• All ingredients not located next to the
equipment
• Spices not located next to each other
• Husband
Underutilized People
• The wife is underutilized in the
process
• Husband/Wife
Resistance to Change
• Wife is resistant to change
• Wife resistant to change in an earlier
wake-up time
• Wife
Customer/Other Risks
• Being late to work
• Appearance unacceptable for video
meetings
• Wife/cat unhappy with the new
process
• Husband/Wife
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
5
Reasons for Kaizen
The purpose of this Kaizen is to reduce waste, save time, standardize the work, organize
the workspace, keep quality consistent, and produce a quality breakfast with minimal variation.
The husband and wife agree that the inconsistencies in quality and time needed has gotten out of
specification.
Desired Conditions
The desired conditions that all parties wish to accomplish with this Kaizen are as follows.
The process needs to output a more consistent product while not compromising on quality. To
have a workspace that is conducive to the task. Standardize the process so anyone, wife, or
husband can make breakfast with the same end product. Have enough flexibility in the process to
allow for substitutions for different flavors or raw ingredients to be added for an enjoyable
amount of variety.
Potential Actions for Improvement
Many possible actions could be implemented to help mitigate the waste in the breakfast
process. Below are the potential efforts that, if implemented, could produce a positive outcome
in the process. Figure A is the prototype of the stove limit indicator to prevent burning. Figure B
shows each person’s tasks to reduce waste and reduce time to complete the overall process.
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
(Figure A: Prototype of Stove Limit Stop)
(Figure B: Load Balanced Task Sheet)
6
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
7
1. Ensure Consistency
1.1. Timing the correct process and keeping track of timings based on the new standard.
1.2. Having the correct measuring utensils within arm’s length of the cooking area.
1.3. Prototyping a limit switch indicator for the stove to make sure the heat will stay the
same.
2. Standardize Work
2.1. Buy and implement a spice rack organizer to find the right spice at the right time.
2.2. Organize spices alphabetically for the majority, but the herbs relevant to the breakfast
process will be in a separate container that is grouped together.
2.3. Have a drawer to the left of the stove that contains all tools and measuring devices
needed to complete the work.
3. Documentation
3.1. Having readily available, accessible, and easy to follow instructions.
3.2. Appropriately schedule the tasks to ensure both husband and wife are not introducing
any time waste into the process.
4. Allow for flexibility
4.1. Keep the process simple enough to allow for seasonal ingredients to be added for variety
without impacting the process steps.
4.2. Swap whole eggs for carton egg whites.
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
8
First Actions
The chart below is a list of prioritized actions that need to happen to reduce waste in the
breakfast process.
Actions and Implementation Chart
Task Description
Person
Responsible
Target
Date
Completion
Date
Time and Develop Baseline
Husband
11/16/2020
11/16/2020
Develop a Load Balanced Task Schedule
Husband
11/16/2020
11/16/2020
11/16/2020
11/16/2020
11/17/2020
11/17/2020
Write Standards for Process
Develop Step Sheet
Husband
Husband
Organizing Workspace with Correct Tools
Wife
11/17/2020
11/17/2020
Prototyping Stove Limit Switch
Husband
11/17/2020
11/17/2020
Find Spice Rack Organizer for Cabinet
Wife
11/17/2020
11/17/2020
Organize Spices Alphabetically
Husband
11/18/2020
11/18/2020
Take Process Specific Spices and Group Together
Husband
11/18/2020
11/18/2020
Swap Whole Eggs for Carton Eggs
Wife
11/19/2020
11/19/2020
Performance Measure After Implementation
The baseline of this process as measured before any improvements or standardization was
timed at 14 minutes. After the implementation of all items in the Action/Implementation Chart
above, the process has been reduced to 9 minutes. Standardizing work and especially having the
tasks load balanced, the work was quickly completed with reduced stress and waste. The new
implementations were able to reduce process time by 35.71%.
MAN4584:W6A3- IMPROVEMENT PROJECT (KAIZEN EVENT)
9
Lessons Learned
In this improvement process, there was a learning curve. Once the process was in place,
and both the husband and wife were familiar with the new steps, it became second nature. By
load balancing the task to utilize both husband and wife, there was a massive reduction in waste.
From 11/20-24, we followed the new process and quickly learned a few lessons. First was how to
move in the kitchen while both of us were working. Avoiding collisions in the kitchen was a
concern!
We tried to swap whole eggs for carton pre-cracked eggs and realized that we are not a
fan. It was too much of a downgrade in quality that we both agreed that it was unacceptable. The
stove limit switch that I 3D printed worked as intended. Not once did we have burnt and unedible breakfast.
As we work on the process, I am optimistic we will get quicker, more efficient, and
continually improve the process.
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Morning Routine Process: Waste Audit & Analysis
Kaitlyn Camp
Saint Petersburg College
MAN4584
April 9th, 2021
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Contents
Waste audit…………………………………………………………………………………………………………………….. 3
Analyze a Waste: ……………………………………………………………………………………………………………. 4
Review Audit …………………………………………………………………………………………………………………. 5
Feedback table ……………………………………………………………………………………………………………….. 6
Lessons Learned: ……………………………………………………………………………………………………………. 6
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Waste audit
Morning routine process
Typical Waste Categories
Overproduction
Excess Inventory
Waiting or Idle Time
Describe Issues Identified
•
•
•
•
•
•
•
•
•
Excess Transport or
Movement
Non-Value Added
Processing
Defects, Mistakes, Rework,
Corrections, Queries,
Inspect Others
Excess Motions
Underutilized People
Resistance to Change
Customer/Other Risks
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Excess coffee powder to make coffee
Prepared too much breakfast for two individuals
All dog food not eaten
Ordered excess coffee/creamer from Starbucks
Excess food from Publix
Excess Dog Food/Treats
Wasting time feeding the dog before walking the dog in the
morning
Feeding son and taking him to the bus station. (Waiting for
the bus / Waiting for son to finish eating)
Wasting too much time in the morning before settling for
work
Too much movements in the morning before commencing
work.
Food ordered from Publix daily
Taking the dog for morning walk daily
Making coffee daily
Feeding and talking the dog for a walk
Checking email while waking up
Coffee too weak / must remake
Excess food Provided to son
Excess food provided to dog
Walking too much within the house to prepare son, breakfast,
feed dog, and do yoga before starting work
Walking to the living area to check emails
Dog food not located near the food bowl
The son is underutilized in this process
Dog is resistant to change walking routine
Son resistant to change in going to bus station alone
Son resilient to change in an earlier wake-up time
Being late for work
Son/dog unhappy with the new process
Son being sent to school in poor mood
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Analyze a Waste:
The utmost important waste area crucial to the procedure consumers (son and dog) is starting the
day with a healthy breakfast. The son needs to be fed and taken to the bus stop at a specific time.
Likewise, the dog expects to be fed and taken for a walk before starting working. Breakfast
directly creates the energy for the entire day and is the foundation of the family’s morning
routine process however, the dog could be fed after the walk and my son could take breakfast to
go. To much time is wasted waiting for the dog to finish eating as well as cooking breakfast and
eating at home. Smoothies or muffins could be on the go healthy breakfast choices.
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Review Audit
The review audit was performed by inquiring from the stakeholders about their input on the
waste audit and analysis. My employer found that my morning routine time waste had a slight
effect on my work performance. My son confirmed the breakfast aspects and morning routine
walk for the dog need to be addressed. However, the dog was satisfied with the limited feedback
offered about the morning routine challenges. The most significant waste elimination was to
address the quality issues with the morning routine time from their feedback. Likewise,
addressing the dog’s walking routine will aid save on time and commence work duties earlier.
Once recognized, the detail was established from my waste audit and focused on these areas
outlined by the stakeholders.
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
Feedback table
CUSTOMER
RESPONSE
Employee
The employer was pleased with the ontime to work.
The employer was satisfied with the
worker’s appearance.
Son
The employer was pleased with the
worker’s alertness level most of the
time
Son was not fulfilled with the breakfast
quality/amount at times.
Son was not fulfilled with the morning
walk routine for the dog. (feels he can
walk the dog alone)
Son was contented with the other
aspects.
Dog
The dog was satisfied with the time and
quantity of food offered.
Lessons Learned:
I have learned a lot from this waste audit analysis. This audit has taught me the
importance of analyzing and measuring aspects and the duration they consume. Until I strode
and analyzed the route, I did not visualize the waste quantity in my process. Feeding my dog
before taking her for a walk is especially a wasteful strategy because I was waiting for the dog to
be finished eating prior to our walk. It is much better to walk the dog and leave the food down
before taking my son to the bus stop. I also utilized my son to be responsible for the walking and
the feeding of the dog therefor, giving me more time to clock in for work. Changing the walking
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
routine for the dog and minimizing the morning breakfast preparing/eating time will perfect the
process and increase the work’s performance and quality.
MAN4584:W4A2- WASTE AUDIT & ANALYSIS: CURRENT STATE
MAN 4584: Process Improvement Methodologies
Assignment 2 (Week 4)
Assignment Value – 25 pts.
Criteria Description Summary
Developing
Proficient
Novice (0 pts.): No effort evaluating
how to apply lessons learned or follow
directions
1. Waste Audit – Identify wastes in (+3.3 pt.) Weakly
(+6.7) Thought about
your defined process. Challenge
identified waste in the
waste in the process well,
current thinking about the process
process. Stayed rather but struggled to challenge
when analyzing potential issues
biased and narrow in
thinking (
35
5 YES
>
10
Check my mail
10 YES
>
15
Make breakfast
20 YES
>
25
Feed Dog
10 YES
>
15
5 YES
>
15
Getting son ready for school
10 YES
>
20
Taking son to the bus stop
10 YES
>
15
Taking the dog for a walk
10 YES
>
15
Coming back home
10 YES
>
15
5 YES
>
10
Coffee
Checking son’s homework
Getting ready for work
Figure 2. Baseline Metrics Data Chart
Outputs and Customers
The Outputs for My Morning Routine Process include the Coffee, full breakfast, the dog
fed, my son provided, his homework checked, he is taken to the bus station and the dog is taken
for a walk. The Customers for this process include my son, me, and the dog.
Inputs and Suppliers
The inputs I have for my Morning Routine Process include yoga, making breakfast,
feeding the dog, checking my son’s homework, getting him ready for school, taking the dog for a
walk, taking my son to the bus station, and returning home to get ready for work. Not all of these
steps are compulsory, and daily, some are done as the need arises. For this process, there are only
four suppliers; Publix, which supplies my household with food, Starbucks, which provides the
family with Coffee; and the leading operator of all the household processes.
W2A1 DEFINE PROCESS & METRICS
6
Decisions and Tasks
The process has many steps to complete each task. The Task vs. Output Matrix (figure 3)
shows the decisions available for each job and what output they will work towards achieving.
Task
Decision
Output Achieved by Task
Check mail
Yes
Employee alert and on-time
Check homework
Yes/No
Son alert
Prepare breakfast
Yes/No
Employee and son alert
Feed dog
Yes
Dog is fed
Take Coffee
Yes
Employee and son fed
Prepare son for school
Yes
Son alert and presentable
Take son to the bus stop
Yes
Son punctual to school
Return home
Yes
Employee alert and on-time
Prepare for work
Yes
Employee alert and on-time
Start to work
Yes
Employee alert and on-time
Figure 3. Task vs. Output Matrix.
Expectations of Customers in the process
In this process, the customers are my son and the dog. Both of them expect to be satisfied
with the process within the specific time every day. My son hopes to be at the bus stop at a
particular time while my dog expects to have been fed and taken for a walk at a specific time.
My employer expects me to have settled to work in my home at one particular time. Both my son
and the dog expect to be fed with breakfast by the time I am ready for work.
Verify Accuracy
The process’s verification has been done using the chart above, and its timing has been
done using the completion chart in the figure below. The completion of the chart will be signed
and dated by the operator.
W2A1 DEFINE PROCESS & METRICS
7
Time Per Step in Process (measured in minutes)
Metrics
Baseline Time
Completed
Actual Time
Acceptable
time
Process Steps YES/NO
Wake UP
1 YES
>
1
Do Yoga
30 YES
>
35
5 YES
>
10
Check my mail
10 YES
>
15
Make breakfast
20 YES
>
25
Feed Dog
10 YES
>
15
5 YES
>
15
Getting son ready
for school
10 YES
>
20
Taking son to the
bus stop
10 YES
>
15
Taking the dog
for a walk
10 YES
>
15
Coming back
home
10 YES
>
15
5 YES
>
10
Coffee
Checking son’s
homework
Getting ready for
work
Household
Members
(Measured in PASS, FAIL)
Son on-time to
bus stop
PASS
Everyone Fed
PASS
Son and I alert
PASS
On-time to work
PASS
Overall Completion Time:
126 Minutes
Operator Name: _________________
Figure 4. Completion Chart
Acceptable Time:
/
Operator Signature: ____________ Time Completed:
191 Minutes
W2A1 DEFINE PROCESS & METRICS
TASK
A Wake up
B Drink Coffee
C Check mail
D Check son’s homework
E Yoga
F Prepare breakfast
G Feed dog
H Prepare son for school
I
Take son to the bus stop
J Take the dog for a walk
K Return home
L Prepare for work
M Start work
8
W2A1 DEFINE PROCESS & METRICS
9
Here the activities are outlined as they happen. With the activities mapped out I can see that I am
proficient in maximizing my time in the morning. As a single parent on a time crunch with a lot
to do in the morning, I have got to a point that I do this routine almost with my eyes closed. I did
not realize I did so much in the morning before mapping it out.
Figure 5. Spaghetti Chart
Lessons Learned
After a careful analysis of my Morning Routine Process, there are several things I have
come to note. I have realized I waste too much time in the morning before settling for work
(McClean et al., 2020). For instance, feeding and walking the dog are activities that my son could
take over in the morning. If I can take a few tasks off my plate I would be able to wake up later
and spend more time having my coffee in the morning. If I regulate my time well, I could have
enough time to prepare for my work (Spall et al., 2018). I have confidence that this discovery
will help me to make some changes in the future to have a more peaceful start to my day.
W2A1 DEFINE PROCESS & METRICS
10
References
McClean, S., Koopman, J., Yim, J., & Klotz, A. C. (2020). How disruptions to our morning
routines harm daily productivity, and what we can do about it. LSE Business Review.
Spall, B., & Xander, M. (2018). My morning routine: How successful people start every day
inspired. Penguin.
W2A1 DEFINE PROCESS & METRICS
11
MAN 4584: Process Improvement Methodologies
Assignment 1 (Week 2)
Assignment Value – 25 pts.
Criteria Description Summary
Developing
Novice (0 pts.): No effort evaluating
how to apply lessons learned or follow
directions
1. Select One Process to Map – Do (+0.6 pt.) Picked a
not pick a huge project nor a process project that may be too
outside ability control to support later overwhelming (should
implementation of at least one
reduce the scope and
improvement or change to the
have more control).
process.
2. Assign Ownership and Roles – (+1 pt.) Missing key
Identify family, co-workers, or other stakeholders and key
stakeholders. Explain project to them details on each role. Did
for approval (share specific steps and not explain efforts to get
timeline). Obtain agree to provide
their agreement and
support on necessary input to
support.
complete the assignments.
3. Analyze Process Boundaries – (+1 pt.) Weak
Identify where this process starts
understanding of process
and stops, as well as other processes boundaries and
that interface with this process.
interfaces (too general)
4. Map Process – select any of 1
(+3.3) Did not visually
tool. Map should be detailed enough map the process
that others could follow your process (provided an outline or
and have the same result.
written summary). Or
may have lacked
sufficient detail. Or may
have not provided any
measures or metrics for
the current process.
5. Verify Accuracy – Walk through
the process definition and metrics
with other process owners or
stakeholder to verify and update for
submission.
6. Identify Lessons Learned Include challenges and experiences
(generalize what you learned for use
in later process improvement
projects).
Proficient
Advanced
(+1.3) Picked a project
(+2) Picked a project to
within the scope but may support the scope of this
struggle with
class. Can implement
implementation (may need changes to the process.
to only make
recommendations).
(+2) Defined each
(+3) Clearly defined
stakeholder and their role stakeholders and explained
(may have missed 1 or 1 efforts to get their
vital detail). Or did not
agreement and support.
explain efforts to get their Clearly defined each
agreement and support
stakeholder role.
well.
(+2) Defined process start (+3) Clearly explained the
and stop boundaries but
project boundaries or
missed some key
limitations for this
interfaces or limitations.
improvement project.
(+6.7) Covered the
(+10) Clearly illustrated
advanced requirements but process:
may have missed 1 key
output/customer,
1. a. outputs and
input/supplier, or
customers
tasks/decisions. May have
not used tool correctly.
b. inputs and suppliers
May have only collected 12 measures or metrics.
1. c. tasks and
decisions to
transform inputs in
the outputs.
d. 3 objectives with actual
measures or metrics for
current process
(+0.6 pt.) Weakly
(+1.3) May have missed 1 (+2) Clearly explained how
explained effort to verify stakeholder (had issues in process was verified
and finalize with
criteria 2 that may have
with other process owners
stakeholders (agreement impacted this).
stakeholders.
vital).
(+0.6 pt.) Very limited (+1.3) Reflected on
(+2) Clearly reflected on
reflection of lessons
challenges and experiences assignment challenges and
learned.
but missed some
experiences generalizing fo
generalization to support future process improvemen
future process
projects.
improvement projects.
W2A1 DEFINE PROCESS & METRICS
7. APA Format – Considered
(+1 pt.) Weakly
punctuation, grammar, spelling,
demonstrated APA
paragraph/sentence structure,
format missing many of
citations, references. Ideally followed the expectations shown
example paper using section/subin the example paper.
sections, figure/table number/title,
1.5-2 line spacing, 1 in. margins,
running header with page number,
etc.
Score:
12
(+2) Demonstrated APA
format well but missed a
couple of the expectations
as shown in the example
paper.
(+3) Effectively
demonstrated APA format.
Included further
expectations like example
paper for format.

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