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kaizen-event-facilitator Kaizen event facilitation skill for rapid improvement workshops and action planning.
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Ocupações relacionadas SOC
Baseado na classificação ocupacional SOC
name kaizen-event-facilitator description Kaizen event facilitation skill for rapid improvement workshops and action planning. allowed-tools Bash(*) Read Write Edit Glob Grep WebFetch metadata {"author":"babysitter-sdk","version":"1.0.0","category":"continuous-improvement","backlog-id":"SK-IE-039"} graph {"domains":["domain:industrial-engineering"],"skillAreas":["skill-area:statistical-analysis","skill-area:organizational-design","skill-area:data-analysis"],"roles":["role:operations-analyst","role:research-engineer"]}
kaizen-event-facilitator
You are kaizen-event-facilitator - a specialized skill for facilitating Kaizen events and rapid improvement workshops.
Overview
This skill enables AI-powered Kaizen facilitation including:
Event planning and preparation
Current state documentation
Waste identification (8 wastes)
Future state design
Action plan development
Standard work creation
Results tracking
Sustainability planning
Capabilities
1. Kaizen Event Planning
import pandas as
from
import
from
import
from
import
List
Dict
@dataclass
class
KaizenEvent
str
str
List
str
List
Dict
int
List
str
str
def
plan_kaizen_event
event: KaizenEvent
"""
Generate comprehensive Kaizen event plan
"""
"week"
4
"activity"
"Define scope and objectives with sponsor"
"owner"
"Facilitator"
"week"
4
"activity"
"Identify team members and get commitment"
"owner"
"Sponsor"
"week"
3
"activity"
"Collect baseline data for metrics"
"owner"
"Team Lead"
"week"
3
"activity"
"Schedule room and equipment"
"owner"
"Facilitator"
"week"
2
"activity"
"Prepare training materials"
"owner"
"Facilitator"
"week"
2
"activity"
"Communicate to affected employees"
"owner"
"Sponsor"
"week"
1
"activity"
"Confirm all logistics"
"owner"
"Facilitator"
"week"
1
"activity"
"Pre-brief team on event objectives"
"owner"
"Facilitator"
"week"
1
"activity"
"Complete 30-day action items"
"owner"
"Team"
"week"
2
"activity"
"First results check"
"owner"
"Facilitator"
"week"
4
"activity"
"30-day review meeting"
"owner"
"Sponsor"
"week"
12
"activity"
"90-day sustainability audit"
"owner"
"Facilitator"
return
"event_summary"
"title"
"scope"
"objectives"
"duration"
f"{event.duration_days} days"
"team_size"
len
"preparation"
"event_agenda"
"followup"
"success_metrics"
def
generate_event_agenda
duration_days: int
"""Generate standard Kaizen event agenda"""
if
5
return
"day_1"
"theme"
"Training and Current State"
"activities"
"time"
"8:00-8:30"
"activity"
"Welcome and introductions"
"time"
"8:30-10:00"
"activity"
"Lean fundamentals training"
"time"
"10:00-12:00"
"activity"
"Go to gemba - observe current state"
"time"
"1:00-3:00"
"activity"
"Document current state process map"
"time"
"3:00-5:00"
"activity"
"Collect time observations"
"day_2"
"theme"
"Waste Identification and Analysis"
"activities"
"time"
"8:00-10:00"
"activity"
"Complete current state map"
"time"
"10:00-12:00"
"activity"
"Identify 8 wastes"
"time"
"1:00-3:00"
"activity"
"Root cause analysis"
"time"
"3:00-5:00"
"activity"
"Prioritize opportunities"
"day_3"
"theme"
"Future State Design"
"activities"
"time"
"8:00-10:00"
"activity"
"Brainstorm improvements"
"time"
"10:00-12:00"
"activity"
"Design future state"
"time"
"1:00-3:00"
"activity"
"Develop action plans"
"time"
"3:00-5:00"
"activity"
"Begin implementation"
"day_4"
"theme"
"Implementation"
"activities"
"time"
"8:00-12:00"
"activity"
"Implement changes"
"time"
"1:00-3:00"
"activity"
"Test and adjust"
"time"
"3:00-5:00"
"activity"
"Document standard work"
"day_5"
"theme"
"Standardize and Report"
"activities"
"time"
"8:00-10:00"
"activity"
"Finalize standard work"
"time"
"10:00-12:00"
"activity"
"Train affected employees"
"time"
"1:00-3:00"
"activity"
"Prepare report-out"
"time"
"3:00-4:00"
"activity"
"Management report-out"
"time"
"4:00-5:00"
"activity"
"Celebrate and close"
elif
3
return
"day_1"
"theme"
"Analyze"
"activities"
"Current state"
"Waste identification"
"day_2"
"theme"
"Improve"
"activities"
"Future state"
"Implementation"
"day_3"
"theme"
"Standardize"
"activities"
"Standard work"
"Report-out"
return
2. Waste Identification (8 Wastes) def identify_wastes (observations: List [Dict ] ):
"""
Categorize observations into 8 wastes (TIMWOODS)
observations: list of {'description': str, 'location': str, 'frequency': str, 'impact': str}
"""
waste_categories = {
'T' : {'name' : 'Transport' , 'description' : 'Unnecessary movement of materials' , 'examples' : []},
'I' : {'name' : 'Inventory' , 'description' : 'Excess inventory beyond immediate need' , 'examples' : []},
'M' : {'name' : 'Motion' , 'description' : 'Unnecessary movement of people' , 'examples' : []},
'W' : {'name' : 'Waiting' , 'description' : 'Idle time waiting for next step' , 'examples' : []},
'O' : {'name' : 'Overproduction' , 'description' : 'Producing more than needed' , 'examples' : []},
'O2' : {'name' : 'Overprocessing' , 'description' : 'More processing than required' , 'examples' : []},
'D' : {'name' : 'Defects' , 'description' : 'Rework, scrap, errors' , 'examples' : []},
'S' : {'name' : 'Skills' , 'description' : 'Underutilized people capabilities' , 'examples' : []}
}
categorized = []
for obs in observations:
category = categorize_waste(obs['description' ])
obs['waste_category' ] = category
waste_categories[category]['examples' ].append(obs)
categorized.append(obs)
summary = []
for code, waste in waste_categories.items():
if waste['examples' ]:
summary.append({
'code' : code,
'name' : waste['name' ],
'count' : len (waste['examples' ]),
'high_impact' : sum (1 for e in waste['examples' ] if e.get('impact' ) == 'high' )
})
summary.sort(key=lambda x: x['count' ], reverse=True )
return {
'waste_categories' : waste_categories,
'observations' : categorized,
'summary' : summary,
'total_wastes_identified' : len (observations),
'top_waste_category' : summary[0 ] if summary else None
}
def categorize_waste (description: str ):
"""Simple keyword-based waste categorization"""
desc_lower = description.lower()
if any (w in desc_lower for w in ['move' , 'transport' , 'carry' , 'travel' ]):
return 'T' if 'material' in desc_lower else 'M'
elif any (w in desc_lower for w in ['wait' , 'idle' , 'queue' , 'delay' ]):
return 'W'
elif any (w in desc_lower for w in ['inventory' , 'stock' , 'wip' , 'pile' ]):
return 'I'
elif any (w in desc_lower for w in ['defect' , 'rework' , 'scrap' , 'error' , 'reject' ]):
return 'D'
elif any (w in desc_lower for w in ['extra' , 'unnecessary' , 'redundant' ]):
return 'O2'
elif any (w in desc_lower for w in ['overproduce' , 'too many' , 'ahead of' ]):
return 'O'
elif any (w in desc_lower for w in ['skill' , 'talent' , 'idea' , 'capability' ]):
return 'S'
else :
return 'O2'
3. Action Plan Development def create_action_plan (improvements: List [Dict ], event_end_date: datetime ):
"""
Create structured action plan from improvements
improvements: list of {'description': str, 'owner': str, 'priority': str, 'effort': str}
"""
actions = []
for i, imp in enumerate (improvements):
if imp['effort' ] == 'just_do_it' :
due_date = event_end_date
category = 'Do During Event'
elif imp['effort' ] == 'short_term' :
due_date = event_end_date + timedelta(days=30 )
category = '30-Day Action'
elif imp['effort' ] == 'medium_term' :
due_date = event_end_date + timedelta(days=90 )
category = '90-Day Action'
else :
due_date = event_end_date + timedelta(days=180 )
category = 'Long-Term Initiative'
actions.append({
'id' : f'A{i+1 :03d} ' ,
'description' : imp['description' ],
'owner' : imp['owner' ],
'priority' : imp['priority' ],
'category' : category,
'due_date' : due_date.strftime('%Y-%m-%d' ),
'status' : 'Not Started' ,
'percent_complete' : 0 ,
'support_needed' : imp.get('support_needed' , '' ),
'success_criteria' : imp.get('success_criteria' , '' )
})
by_category = {}
for action in actions:
cat = action['category' ]
if cat not in by_category:
by_category[cat] = []
by_category[cat].append(action)
return {
'all_actions' : actions,
'by_category' : by_category,
'summary' : {
'total_actions' : len (actions),
'during_event' : len (by_category.get('Do During Event' , [])),
'30_day' : len (by_category.get('30-Day Action' , [])),
'90_day' : len (by_category.get('90-Day Action' , [])),
'long_term' : len (by_category.get('Long-Term Initiative' , []))
}
}
4. Results Tracking def track_kaizen_results (baseline: Dict , current: Dict , targets: Dict ):
"""
Track Kaizen event results against baseline and targets
"""
results = []
for metric, baseline_value in baseline.items():
target_value = targets.get(metric, baseline_value)
current_value = current.get(metric, baseline_value)
if baseline_value != 0 :
improvement_pct = (baseline_value - current_value) / baseline_value * 100
target_improvement_pct = (baseline_value - target_value) / baseline_value * 100
else :
improvement_pct = 0
target_improvement_pct = 0
better_is_lower = target_value < baseline_value
if better_is_lower:
target_met = current_value <= target_value
else :
target_met = current_value >= target_value
results.append({
'metric' : metric,
'baseline' : baseline_value,
'target' : target_value,
'current' : current_value,
'improvement_percent' : round (improvement_pct, 1 ),
'target_improvement_percent' : round (target_improvement_pct, 1 ),
'target_met' : target_met,
'status' : 'green' if target_met else 'yellow' if abs (improvement_pct) > 0 else 'red'
})
targets_met = sum (1 for r in results if r['target_met' ])
return {
'metrics' : results,
'summary' : {
'metrics_tracked' : len (results),
'targets_met' : targets_met,
'target_achievement_rate' : round (targets_met / len (results) * 100 , 1 ) if results else 0
}
}
5. Standard Work Documentation def create_standard_work (process_steps: List [Dict ], takt_time: float ,
cycle_time: float , work_in_process: int = 1 ):
"""
Create standard work documentation
process_steps: list of {'step': int, 'description': str, 'time': float, 'key_points': list}
"""
total_time = sum (s['time' ] for s in process_steps)
manual_time = sum (s['time' ] for s in process_steps if not s.get('machine_time' , False ))
walk_time = sum (s.get('walk_time' , 0 ) for s in process_steps)
standard_work = {
'header' : {
'process_name' : '' ,
'takt_time' : takt_time,
'cycle_time' : cycle_time,
'operators' : 1 ,
'standard_wip' : work_in_process
},
'time_summary' : {
'total_cycle_time' : round (total_time, 1 ),
'manual_time' : round (manual_time, 1 ),
'walk_time' : round (walk_time, 1 ),
'takt_vs_cycle' : round (takt_time - cycle_time, 1 )
},
'sequence' : [],
'quality_checks' : [],
'safety_points' : []
}
cumulative = 0
for step in process_steps:
cumulative += step['time' ]
standard_work['sequence' ].append({
'step' : step['step' ],
'description' : step['description' ],
'time_seconds' : step['time' ],
'cumulative_time' : cumulative,
'key_points' : step.get('key_points' , []),
'symbol' : step.get('symbol' , 'operation' )
})
for kp in step.get('key_points' , []):
if 'quality' in kp.lower() or 'check' in kp.lower():
standard_work['quality_checks' ].append({'step' : step['step' ], 'point' : kp})
if 'safety' in kp.lower() or 'caution' in kp.lower():
standard_work['safety_points' ].append({'step' : step['step' ], 'point' : kp})
return standard_work
def create_standard_work_combination_sheet (operators: List [Dict ], takt_time: float ):
"""
Create standard work combination sheet for multiple operators
"""
combination = {
'takt_time' : takt_time,
'operators' : []
}
for op in operators:
op_data = {
'operator' : op['name' ],
'tasks' : op['tasks' ],
'total_manual_time' : sum (t.get('manual' , 0 ) for t in op['tasks' ]),
'total_walk_time' : sum (t.get('walk' , 0 ) for t in op['tasks' ]),
'total_wait_time' : sum (t.get('wait' , 0 ) for t in op['tasks' ]),
'total_cycle_time' : sum (t.get('manual' , 0 ) + t.get('walk' , 0 ) + t.get('wait' , 0 ) for t in op['tasks' ])
}
op_data['utilization' ] = round (op_data['total_cycle_time' ] / takt_time * 100 , 1 )
combination['operators' ].append(op_data)
return combination
6. Sustainability Assessment def assess_sustainability (event_id: str , days_since_event: int ,
audit_findings: List [Dict ] ):
"""
Assess sustainability of Kaizen improvements
"""
categories = {
'standard_work_adherence' : [],
'metrics_maintained' : [],
'visual_management' : [],
'employee_engagement' : [],
'system_support' : []
}
for finding in audit_findings:
cat = finding.get('category' , 'standard_work_adherence' )
if cat in categories:
categories[cat].append(finding)
scores = {}
for cat, findings in categories.items():
if findings:
positive = sum (1 for f in findings if f.get('status' ) == 'maintained' )
scores[cat] = round (positive / len (findings) * 100 , 1 )
else :
scores[cat] = None
valid_scores = [s for s in scores.values() if s is not None ]
overall = round (sum (valid_scores) / len (valid_scores), 1 ) if valid_scores else 0
return {
'event_id' : event_id,
'days_since_event' : days_since_event,
'category_scores' : scores,
'overall_sustainability_score' : overall,
'status' : 'sustained' if overall >= 80 else 'at_risk' if overall >= 60 else 'degraded' ,
'findings' : categories,
'recommendations' : generate_sustainability_recommendations(scores, overall)
}
def generate_sustainability_recommendations (scores, overall ):
recommendations = []
if scores.get('standard_work_adherence' , 100 ) < 80 :
recommendations.append("Reinforce standard work training and daily audits" )
if scores.get('visual_management' , 100 ) < 80 :
recommendations.append("Update and maintain visual management boards" )
if scores.get('employee_engagement' , 100 ) < 80 :
recommendations.append("Increase team involvement in daily improvement activities" )
if overall < 60 :
recommendations.append("Consider refresher Kaizen event to restore gains" )
return recommendations
Process Integration This skill integrates with the following processes:
kaizen-event-execution.jscontinuous-improvement-program.jsstandard-work-development.js
Output Format {
"event_plan" : {
"title" : "Assembly Cell Improvement" ,
"duration" : "5 days" ,
"objectives" : [ "Reduce cycle time 20%" , "Eliminate 3 wastes" ]
} ,
"waste_identification" : {
"total_identified" : 15 ,
"top_category" : "Motion" ,
"high_impact" : 5
} ,
"action_plan" : {
"total_actions" : 22 ,
"during_event" : 8 ,
"30_day" : 10 ,
"90_day" : 4
} ,
"results" : {
"metrics_improved" : 4 ,
"targets_met" : 3 ,
"overall_improvement" : "25%"
}
}
Best Practices
Prepare thoroughly - 80% of success is in preparationGo to gemba - Observe reality, not reportsInvolve operators - They know the problemsDo, don't discuss - Implement during the eventMeasure before/after - Data proves improvementFollow up - Sustainability requires attention
Constraints
Requires dedicated team time
Management support essential
Scope must be achievable in timeframe
Not all problems suit Kaizen events
