FLASH METHOD: A RAPID CONTINUOUS IMPROVEMENT APPROACH BASED ON STRUCTURED PROBLEM DEFINITION AND RAPID PROTOTYPING

Continuous improvement methodologies such as Kaizen, Lean Manufacturing, and Six Sigma have been widely applied to improve productivity and quality in manufacturing systems. However, small and medium-sized enterprises often face difficulties implementing structured improvement projects due to limited resources, lack of specialized knowledge, and operational constraints. This study proposes the FLASH Method (Fast Lean Analysis for Systemic Improvement), a rapid improvement framework designed to identify operational problems and validate solutions through structured observation and rapid prototyping. The methodology integrates principles of Kaizen, root cause analysis, and the PDCA cycle, incorporating two distinctive elements: the Problem Definition Reliability Indicator (ICDP) and the Rapid Pilot stage, which allows testing improvement hypotheses through low-cost prototypes before implementing permanent solutions. The method was applied during the implementation of a continuous improvement project in 2025 in three manufacturing companies addressing different operational issues: material waste, production delays due to tool searching, and product defects. The results demonstrate that the method enables rapid identification of operational problems and validation of practical solutions without requiring significant investments. The findings suggest that the FLASH Method can serve as a practical framework for accelerating continuous improvement initiatives in organizations with limited experience in Lean methodologies.