Unless this is 5S event, the area should be generally uncluttered and free of unneeded items. Otherwise, valuable Kaizen time will be spent cleaning up the area instead of implementing improvements. If the area needs a 5S effort, this is something that could be done ahead of time, or as a separate Kaizen event, prior to attempting a flow or cell design activity.

Take a high-level look at the impact that this Kaizen will have on upstream and downstream processes. Remember that usually production will be continuing in this area, so try to anticipate any negative impacts. Sometimes it may be necessary to have some WIP build up in order to supply the downstream processes while the upstream process is being worked on.

Finally, anticipate the impact on other shifts. Don’t leave them out of the loop! Try to have representation from all shifts on the Kaizen team. Make sure that the supervisors on other shifts are clearly aware and supportive of the changes that are taking place.