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Kaizen Desk Reference Standard
by Raphael L. Vitalo, Ph.D., Frank Butz, Joseph P. Vitalo
Kaizen Full Cover
This is the first complete step-by-step guide for doing Kaizen. It includes a fully described case example of an actual Kaizen event. It explains in detail how to evaluate opportunities, prepare for events, build and lead Kaizen teams, make and measure business improvements, and follow up on events so that the benefits they produce sustain. Its methodology has been proven in over 150 Kaizen events conducted in the U.S., Canada, Europe, and the U.K. The electronic book comes with the Kaizen Tool Kit, a set of 62 electronic tools that support your success.
Print book available Now    
Electronic book available Now Price: $4.99    

Tool Kit
About the

Product Details - Print Edition

Paperback: 456 pages; Dimensions 2" x 11" x 8.5"
CD-ROM: Kaizen Tool Kit included with book
Publisher: Lowrey Press, April 2003
ISBN: 0-9722810-4-5
LCCN: 2003101105



Product Details - Electronic Book

Format: Acrobat Reader (PDF)
File Size: 7.5Mb (includes Kaizen Tool Kit)
Printable: No
Macintosh Compatible: No
Windows Compatible: Yes
Required Software: Acrobat Reader 4.0 or higher
Publisher: Lowrey Press, March 2003
ISBN: 0-9722810-3-7
Price: $4.99


Book Contents

Preface v Read
Introduction 1 Read
Overview of Kaizen 9    
Kaizen in Action 21 Read
Milestone A. Document a Scope for the Kaizen Event 67    
  Task A1. Understand the Scope Document 91    
Milestone B. Analyze Whether to Conduct the Kaizen Event 111    
Milestone C. Prepare for the Kaizen Event 145    
Milestone D. Perform the Kaizen Event 163      
  Task D1. Focus the Kaizen Event 189      
    Step D1-S1. Build a Description of the Target Work Process 197      
    Step D1-S2. Walk Through the Target Work Process 215      
    Step D1-S3. Build the Mission Statement 241      
    Step D1-S4. Set Goals for the Kaizen Event 253      
    Step D1-S5. Define the Do's and Don'ts 261      
  Task D2. Evaluate the Target Work Process 267      
  Task D3. Solve the Performance Issue 311      
    Step D3-S3. Conduct an Experiment 323      
  Task D4. Act to Improve the Target Work Process 333 169k   Get Acrobat Reader
    Step D4-S1. Measure Results 351      
    Step D4-S3. Conduct a Pilot 373      
Milestone E. Institutionalize the Process Improvements 383      
Customizing the Kaizen Process 389      
Ending Note: Of Sanctity and Sacrilege 415      
Glossary 417      
Index 427 52k   Get Acrobat Reader
Acknowledgments 445      
About the Authors 447      
User Evaluation and Feedback Form 449      

Kaizen Tool Kit Contents

The Kaizen Tool Kit is a set of 62 electronic tools that support your success in doing Kaizen. Some tools are static (e.g., handouts, guides, roles descriptions) for use in preparing yourself, educating others (e.g., the event coordinator or sponsor), and your Kaizen team. Some tools are dynamic meaning they are forms that you populate with information specific to your event and most of these perform useful operations (e.g., addition, subtraction, computation of value added and waste). The static tools are in PDF format. The dynamic tools are in MS Word and Excel formats. 20 of these tools may be tailored to your company's needs.


Action Plan Example
Action Plan Template
Certificate of Recognition
Checklist for Preparing the Setting
Consistency of Scope Information
Design of the Pilot
Detecting Value-Added Work and the Forms of Waste Exercise
Direction for the Kaizen Event
Do's and Don'ts
Example: Action Plan
Experiment, Design/Results
Goals for the Event
Guide: Building an Action Plan
Guide: Designing the Experiment
Guide: Distance Measurement Role
Guide: Documentation Role
Guide: Documenting Decision Logic
Guide: Explaining What Kaizen Is
Guide: Judging Readiness for the Event
Guide: Machine Observer Role
Guide: Observe First
Guide: Photographer Role
Guide: Planning the Pilot
Guide: Process Observer Role
Guide: Questions That Could Be Asked During the Personal Interview
Guide: Questions That Could Be Asked During the Walk Through
Guide: Spaghetti Charting Role
Guide: The Event Coordinator Role
Guide: The Role of Providing Scope Information
Guide: Timekeeper Role
Guide: Understanding the Forms of Waste
Guide: Utility Role
Guide: Workplace Layout Role
Kaizen News - Day 1
Kaizen Participant Feedback Form

Kaizen Participant Feedback Summary Form
Kaizen Post-Event Flyer
Kaizen Pre-Event Flyer
Kaizen Scope Document
Kaizen Summary
Leave-Behind Measure
Logistics Checklist
Machine Analysis Sheet
Machine Observations Data Sheet
Mission Statement
Parking Lot Issues
Pilot , Guide: Planning the
Pilot , Results of the
Prioritized List of Process and Workplace Improvement Ideas
Process Analysis Sheet
Process Observations Data Sheet
Results of Judging the Appropriateness of Doing the Kaizen Event
Scope Document
Scope Statement Checklist
Sharpening Observation Skills Exercise
Stakeholder Perspective
Strawperson Direction for the Proposed Event
Summary of Findings
Summary of Monetary Benefits
Summary of Operating Improvements
Template for Describing a Work Process
Template for Leave-Behind Measure
Timeline for Completing a Kaizen Event
Travel and Shipping Arrangements Job Aid
User Evaluation and Feedback Form
Using the Machine Analysis Sheet
Using the Process Analysis Sheet
Waste Observed During Walk Through Categorized by Type
Working With Others 10 Minute Review - Instructor Guide
Working With Others 10 Minute Review - Visuals

Once you have installed the Kaizen Tool Kit you purchase, be sure to download the latest update to the Kaizen Tool Kit so that you have all the newly added tools. Tool Kit updates are free. Download them from the Share/Learn area of this web site.


About the Authors

Raphael L. Vitalo received his doctorate in psychology from the University of Massachusetts at Amherst. He has authored over 50 professional articles, technical reports, and chapters in the areas of psychology, organizational consulting, work process improvement, information systems, and artificial intelligence. Over his 25 years of consulting experience, he has designed, managed, and implemented over 350 projects serving public and private companies in the areas of organizational effectiveness, performance management, workforce productivity, business process reengineering, knowledge engineering, information systems design, and expert systems development. Dr. Vitalo has trained Kaizen leaders in the United States and Europe. He has been the lead consultant in designing and implementing a number of multi-year CI projects in human services and the private sector. One such project was a 10-year CI initiative using Working With Others productivity improvement sessions that yielded a return on investment of 9.6 to 1 in just its first year and was credited by the business itself for adding 5% productivity improvement every year of its operation. Another multi-year effort applied Lean/CI approaches in mental health treatment. This initiative improved the success of treatment outcomes by 31% (from 70% to 92%), reduced dropout from treatment by 50%, expanded the number of people served with the same level of staff by 20%, and produced a per unit cost of care that was 56% below the national average. Most recently, he was the lead consultant in designing and supporting the implementation of Lean/CI initiative in a 4 billion dollar (USD) business component of a Fortune 200 company. This global initiative yielded $7.6 million dollars (USD) in savings during its first year of implementation, $21.1 million in its second year, and over $40 million in its third year. Dr. Vitalo is currently the president of Vital Enterprises.

Frank P. Butz is a senior Lean/CI consultant with over 32 years in management roles with a Fortune 200 company including seven years as a manufacturing plant superintendent. His facility was responsible for the worldwide fabrication of equipment including liquefied natural gas heat exchangers, air separation plants, and other cryogenic storage equipment. Frank was chosen as the Corporate Senior Tool Expert for his company’s global Lean/CI initiative. There he managed a sixteen-person team for the worldwide application Continuous Improvement Tools. Since 1997, Frank has conducted over 120 lean tool events in Value Stream Mapping, Workplace Organization and Visual Control, Kaizen, Total Productive Maintenance, among others. He developed and implemented a comprehensive training and certification program which, to date, has prepared over 200 Lean tool facilitators. He is a co-author of the Kaizen Desk Reference Standard, the only complete and systematic guide to doing Kaizen. Events using this book’s methodology have produced bottom-line results for service and manufacturing companies worldwide.

Joseph P. Vitalo is a certified Kaizen leader and trainer who is also trained in demand flow technology and workplace organization and visual controls. He has planned and led Kaizen Events in the United States, Canada, Europe, and the United Kingdom. His last 23 events produced total annualized savings of $2.1 million. He has co-led Kaizen leader training events which have prepared more than 40 new Kaizen leaders. Mr. Vitalo is currently a lean consultant and trainer with Vital Enterprises. In addition to training in productivity improvement tools, Joe instructs teams in knowledge acquisition, best practice sharing, learning from performance, and working with others.