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Kaizen: Let the people who see the waste fix it.

From a quick Point Kaizen at one workstation to larger improvements across the plant. Operators submit from a phone, supervisors score and approve, management sees every site in one report.

Kaizen: Parts out of reach at assembly station 3
Originator Tom Reyes
Location Torrance
Created 8/24/2026
Team Assembly Line 2
Category Ergonomics
Open 25 days
Kaizen Stages
Draft
Go for implementation
Implemented
Published
Improvement idea (before)
Bins behind and beside the operator. Twisting and reaching back every cycle.
Bins behind and beside the operator. Twisting and reaching back every cycle.
Results (after)
Bins on a rail in front of the fixture. Cycle 40% faster, no twisting.
Photo after implementation
Bins on a rail in front of the fixture. Cycle 40% faster, no twisting.
SM
Sarah Mitchell @Mike Turner Good idea, please review. Can maintenance mount a bin rail this month?
Kaizen scoring Locked
Impact
1 3 5
Originality
1 3 5
Feasibility
1 3 5
Total score – 11
Actions
Mount a bin rail in front of the fixture M. Turner 9/4
Update the work instruction and retime the cycle S. Mitchell 9/11
Impact Summary
ImpactSaving / BenefitApplicable period Cycle time –−40% –from 9/2026 Hours saved –310 h / year –9/2026 – 8/2027 Safety risks –−1 (ergonomics) –from 9/2026
Submit
Approve & score
Implement
Publish

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15,000+Active users 59Countries 190,000+Problems solved

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 is continuous improvement software for the whole company, from the shop floor to the boardroom. Every employee submits improvement ideas from any device. Each idea is scored, approved, and tracked from concept through completion to verified results. Proven improvements move to a Published stage, where other sites can find them and copy them.

Anyone can submit ideas
Structured evaluation criteria
Implementation progress tracked
Savings and impact metrics tracked

Point Kaizen in TeamGuru

Point Kaizen: the operator spots it, the whole company sees the result

Point Kaizen is the smallest improvement there is: one person, one spot, one change. A parts bin behind the operator's back, a faded walkway line, a label nobody can read. The operator sees it every shift. What stops the fix is the paperwork. Here is how one small idea travels through TeamGuru, from a phone on the shop floor to the report on the plant TV.

  1. 1

    The operator writes it down in two minutes

    A title, one sentence and a photo of how it looks today. In the operator's own language, from a phone or the terminal at the line. Operators work as light users: a simpler screen with only what the shop floor needs, at a lower license price.

    New Point Kaizen
    Title
    Parts out of reach at assembly station 3
    Short description
    Two bins sit behind and beside me. Every cycle I twist and reach back for parts. Put them on a rail in front of the fixture.
    Category Ergonomics
    Photo, before
    reaching back, twisting every cycle
    Submit
    Light user · simplified screen
  2. 2

    Your approval path, with your stage names

    Draft, Go for implementation, Implemented, Published. That is how one manufacturer set it up. Yours can have three stages or six, named the way your people talk. The supervisor comments right on the kaizen and @mentions whoever needs to look.

    Kaizen Stages
    Draft
    Go for implementation
    Implemented
    Published
    SM
    Sarah Mitchell

    @Mike Turner Good idea, please review. Can maintenance mount a bin rail this month?

  3. 3

    Every line scores it the same way

    Impact, originality, feasibility: 1, 3 or 5 points each, and a total the committee can sort by. In later stages the score locks, so nobody rewrites it after the fact. Set the criteria and the points to fit your program.

    Kaizen scoring
    Scoring is locked in this stage
    Impact
    High impact: shorter cycle, lower injury risk
    135
    Originality
    Incremental idea
    135
    Feasibility
    Ready to deploy
    135
    Total score 11 / 15 points
  4. 4

    Before, after, and who did what

    Each action has a name, a due date and a percentage done, and it sits in the same action lists as the rest of the plant's work. When it is finished, the after photo goes next to the before photo. Anyone sees what changed in three seconds.

    reaching back, twisting every cycle
    Before reaching back, twisting every cycle
    bins in front of the fixture, cycle 40% faster
    After bins in front of the fixture, cycle 40% faster
    Actions
    • Mount a bin rail in front of the fixture 9/4 100 %
    • Update the work instruction and retime the cycle 9/11 60 %
  5. 5

    Management sees the whole company on one page

    The Reports module pulls every kaizen into one report: open and closed by site, new ideas per year, and who is submitting them. Put it on the TV at the SQDIP board, send it as a PDF every month, and thank the people at the top of the list by name.

    Kaizen Update for September 2026
    Open kaizen by site
    12
    7
    5
    3
    2
    Torrance Monterrey Brno Pune Suzhou
    New kaizen per year
    41
    68
    95
    132
    118
    2022 2023 2024 2025 2026
    Closed kaizen by site
    38
    29
    24
    15
    9
    Torrance Brno Monterrey Pune Suzhou
    New kaizen by originator
    14
    11
    9
    7
    6
    J. Kim T. Reyes K. Brooks A. Singh L. Chen
    Confidential · For internal use only · Page 1

The screens above show one customer's setup. Stages, scoring criteria, form fields and the language of the form are configured to fit your program, and the Impact Summary for savings is a section you switch on when you need it.

What you get

Every operator takes part

Operators work as light users: a cheaper license and a screen with only what the shop floor needs. That makes it realistic to put the whole workforce on the system, not only the supervisors.

One scoring rule for every site

Impact, originality and feasibility, 1, 3 or 5 points each, the same in every plant. Ideas from different sites become comparable, and once a decision is made the score locks.

Nothing stalls between stages

Every kaizen shows its stage and how long it has been open. Every action has an owner, a due date and a percentage done, in the same action lists as the rest of the plant's work.

Financial benefit tracking

Switch on the Impact Summary and each kaizen records what it changed: cycle time, hours, scrap, safety risk, with the period it applies to and a weekly or monthly savings series. Automatic calculations in the metrics module can roll it up by site and year, for the same dashboards and reports as the plant KPIs.

Presenting this to your team or management?

Download a two-page overview of the Kaizen module to share or print.

Download PDF

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. Switch on the Impact Summary section and each kaizen records its impact type, the saving or benefit and the period it applies to, with a savings series entered weekly or monthly. With automatic calculations in the metrics module you can roll the savings up across kaizens, sites and years and show them in dashboards and reports.
How do we replicate good ideas across sites? +
Give proven kaizens a stage such as Published. Other sites find them in the Kaizen list and reports, see the before and after photos and the actions, and copy what works. There is no automatic notification to other sites today.
Can we run Kaizen events (workshops) through the system? +
Yes. A workshop runs in the same Kaizen document: assign the team, plan the work as actions with an owner and a due date, and record the before and after, plus any financial benefit in the Impact Summary.
Do operators need a full license to submit ideas? +
No. Operators can work as light users: a simpler screen with what the shop floor needs, at a lower price than a full license. That is what makes it realistic to put every operator on the system, not only the supervisors.

See Kaizen in action

Book a personalized demo and see how TeamGuru handles Kaizen for teams like yours.