+ s |kaizen...¡ kaizen improves product quality ¡ results in higher employee moral and job...
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O le h :
Debr ina P. Andr iani Te k n ik Indus t r i Un i ve r s i t as B raw i jaya þ de br ina@ ub .ac . id
+ S | K A I Z E N C O N T I N U O U S I M P R O V E M E N T I S T H E R E S U L T O F C O N T I N U O U S I N V O L V E M E N T
T O T A L Q U A L I T Y M A N A G E M E N T
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TL
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¡ Kaizen- An Introduction ¡ What Is Kaizen ¡ Features Of Kaizen ¡ Phases In Kaizen ¡ Benefits Of Kaizen ¡ Contents Of An Operation ¡ What Is Obvious Waste? ¡ Workplace Organization ¡ Workflow – Line Balancing ¡ Traditional Method Vs Kaizen ¡ 10 Ground Rules For Kaizen ¡ 5 ‘S’ In KAIZEN ¡ Pit Falls In Kaizen
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Masaaki Imai is known as the
developer of Kaizen.
KAIZEN- AN INTRODUCTION
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WHAT IS KAIZEN
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KAIZEN
LowCost ContinuousImprovement
Kaizen denotes continuous improvement. Kaizen aims to eliminate all wastes in business processes through standardization in the processes and activities of a business entity. Change making and result monitoring make Kaizen highly effective.
WHAT IS KAIZEN?
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WHAT IS KAIZEN?
Assess/Reassess
Plan and Design
Implement
Evaluate
K a i z e n a c t i v i t i e s t h a t a d d r e s s i s s u e s o v e r a period of one week had become the industry norm and they had been named a s ‘K a i z e n e v e n t s’ . These small models are u s e d t o u n d e r s t a n d problems and issues in the business processes, arrive at so lut ions , and apply t h e m t o i m p r o v e t h e processes and el iminate wastes.
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¡ So basically kaizen is small incremental changes made for improving productivity and minimizing waste.
¡ Kaizen has three main principles: § Consider the process and the results. § The need to look at the entire process of the job at hand and to
evaluate the job as to the best way to get the job done. § Kaizen must be approached in such a way that no one is
blamed and that the best process is put into place.
WHAT IS KAIZEN?
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FEATURES OF KAIZEN • Can be used in both manufacturing and non-
manufacturing environments Widely applicable
• Kaizen events will generate quick results, Measurable results, Establish the baseline, and measure the change!!!
Highly effective & results oriented.
• Every member of a Kaizen Team will walk away from the event learning something new! !
A Learning Experience
• Team members can be from various functions of the business. Top management participation is encouraged.
Team based & cross functional
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PH
ASES IN
K
AIZEN
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A.) Select an Event B.) Plan an Event
C.) Implement an Event D.) Follow-up to an Event
THESE STEPS ARE SHORTEN INTO :
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¡ Kaizen Reduces Waste- like inventory waste, time waste, workers motion
¡ Kaizen Improves product quality
¡ Results in higher employee moral and job satisfaction,.
¡ Toyota is well-known as one of the leaders in using Kaizen. In 1999 at one U.S. plant, 7,000 Toyota employees submitted over 75,000 suggestions, of which 99% were implemented.
BENEFITS OF KAIZEN
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CONTENTS OF AN OPERATION
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WHAT IS OBVIOUS WASTE?
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WORKPLACE ORGANIZATION
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WORKFLOW – LINE BALANCING
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SMED QUICK TOOL CHANGEOVER
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TRADITIONAL METHOD VS KAIZEN
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10 GROUND RULES FOR KAIZEN
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5 ‘S’ IN KAIZEN ¡ 5S is a method for organizing a workplace,
especial ly a shared workplace (l ike a shop f loor or an off ice space), and keeping i t organized.
¡ To take the concept of Kaizen performance to i ts ult imate level of simplicity, i t offered the fol lowing "5S" steps
§ Sorting keeping only essential items § Simplifying eliminates extra motion. § Sweeping keep the workplace clean
§ Standardizing standardized work practices § Sustaining maintaining and reviewing standards
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¡ Resistance to change
¡ Lack of proper procedure to implement
¡ Too much suggestion may lead to confusion and time wastage
PIT FALLS IN KAIZEN
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SELESAI