Following a mapping exercise at an automotive part supplier it was decided to stage a 1+2+2-day series of kaikaku events. Initial mapping had revealed a large proportion of movement wastes and double handling, and apparently large inventories.

The findings of the original mapping exercise were presented to a group of senior and middle managers who decided that 1+2+2 type event would be most suitable for their situation which included a relatively low awareness level of JIT / Lean Manufacturing / Waste concepts, fairly complex product routings, and a number of machines that were fixed to the floor. The target area for the exercise was identified as being one where there appeared not only to be good opportunity, but where the product range was limited to a family of products with similar routings.

The team to carry out the event was identified. It comprised the external facilitator, the kaizen facilitator from the company, the cell supervisor, an industrial engineer from another site in the same group, an accountant from the factory, and three cell operators. All had to commit to being completely free of other duties for the duration of the events, although the industrial engineer and accountant were permitted to attend half-hour morning meetings.