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Kaizen

Capture improvement ideas from every level. Evaluate, implement, and measure results. Turn frontline insights into lasting gains.

Reduce changeover time on Press Line 2KZ-0312
Submitted byL. Roberts
AreaStamping
Open18 days
TeamProduction
DeptPress Shop
EfficiencyOEE
Kaizen Stages
Under evaluation
Improvement Idea
Implement SMED methodology to reduce die changeover from 45 min to under 15 min by pre-staging tools and standardizing adjustment sequence.
Proposal:Separate internal and external setup, pre-stage tooling, standardize adjustments.
Expected:70% changeover reduction. 2 to 4 changeovers per shift.
Comments
KW
K. Walker
Shadow study shows 60% of changeover is external setup that can be done while press is running.
RB
R. Bennett
Similar approach cut changeover by 70% on Press Line 4 last quarter.
Actions0 of 3
Separate internal and external setup tasksLR
Pre-stage dies and tooling on cartKW
Create standardized adjustment checklistRB
Impact
3/2026
BaseTargetActual
Changeover time45 min15 min18 min
Changeovers/shift243
Savings$85K/yr$62K/yr
Submit
Evaluate
Implement
Review Impact

Best ideas had nowhere to go

The people doing the work saw the waste every day. But there was no way to submit an idea, no process to evaluate it, and no feedback loop. So they stopped suggesting. Improvement became a top-down initiative instead of a daily habit.

Now every idea has a path

TeamGuru gives every employee a simple way to submit improvement ideas from any device. Each idea is evaluated, prioritized, and tracked from concept through completion to verified results. Successful improvements are flagged for replication across sites.

Anyone can submit ideas
Structured evaluation criteria
Implementation progress tracked
Verified savings measured

Common questions

How do employees submit ideas? +
Through a simple web form accessible on any device. The form captures the problem, the proposed solution, the expected benefit, and the affected area. It takes less than two minutes.
Who evaluates and approves ideas? +
You define the evaluation process: direct manager, improvement committee, or cross-functional team. Criteria and scoring rubrics are configurable.
Can we track cost savings from improvements? +
Yes. Each implemented Kaizen can include verified savings (time, cost, quality). These aggregate into organizational improvement ROI reports.
How do we replicate good ideas across sites? +
Successful Kaizen implementations can be flagged for replication. The system notifies other sites about proven improvements relevant to their operations.
Can we run Kaizen events (workshops) through the system? +
Yes. The module supports both small daily improvements and larger Kaizen event workshops with team assignments, timelines, and structured outcomes.

See Kaizen in action

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