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Kaizen

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Contents

What is Kaizen?

Aspects ofKaizen principle.

Kaizen approach. Kaizen focus.

Key elements ofKaizen.

Kaizen Umbrella.

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What is Kaizen? Created in Japan following WW II.

Kai => School Zen => Wisdom

Word means continuous incrementalimprovement.

It is a system that involves every employee fromupper to lower to come up with smallimprovement ideas.

Philosophy :- Do it better, make it better,improve it.

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Aspects of Kaizen Principle

Quality awareness,

quality control.

Standardization.

Total employee

involvement.

Effecti

ve leaders

hip.

Good labor

relationship.

Adaptability to

changing

environment. Process driven.

Reducing waste.

Cust

omer

orientati

on.

Visibility & control.

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KaizenA

pproach1. Continuous improvement rather than

innovation.

2. Pr

ocess dri

ven, n

ot results dri

ven.3. The next process is customer.

4. Dont pass the defective work to the nextperson down the line.

5. Standardization.

6. Reducing waste.

7. Getting things right the first time.

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1. Continuous improvement rather

than innovation

Innovation Kaizen

1. Creativity Adaptability

2. Individualism Teamwork Systems approach

3. Specialist - oriented Generalist oriented

4. Technology oriented People oriented

5. Information: closed &

proprietary

Information: open, shared

6. Functional oriented Cross functional orientation

7. Sees new technology Building on existing technology

8. Limited feedback Comprehensive feedback

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2. Process driven, not results

driven

Focus on process, results are

automatically improved.

Obsession with results are short term

focus on profit. Management loose sight of

establishing good working practices of

motivation.

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3.The next process is customer

Phrase coined by Haoru Ishikwa to pave

the way for breaking down department

barriers, and prompting cross-functional

management.

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4. Dont pass the defective work to the

next person down the line

It is an absolute criterion for continuous

improvement.

(A person cant endlessly firefight

against the incompetence or

negligence of others. )

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5.Standardization

First discover your process, i.e., find out what it is thatyou are doing.

Find out performance measures, and the level at whichthings are currently being done.

Ifno standards are in place, then use your existingperformance as your current level.

Find out the ways in whichoutput can be improved.

Initiate improvements and achieve higher standards,which is to be used as the next point of reference forfurther improvements.

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6.Reducing waste

Wastes ofwork force through inadequate training &development. (Man)

Waste due to non-value-adding tasks. (Method)

Waste due to improperfunctioning or/& underutilizationofmachines. (Machines)

Waste ofgoods in warehouse or deterioration over time.(Materials)

General waste through lack ofmeasurement. Waste in WIP as quality has not been built & reliance is

on inspection. (Quality procedure)

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7. Getting things right the first time

Involve employees, motivate them, train them,

make them problem conscious, give them

ownership on a local as well as global level. Involve customer. Reduce wastes by adhering

closely to the customer requirement.

Concentrate on N=2 principle only the first &

last item of the batch to be inspected.

Treat the source not the symptoms.

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Focus of Kaizan

Value added & non-value added work activities.

Principles ofmotion study.

Principles ofmaterial handling. Documentation ofSOP.

Five S, work place organization.

JIT.

Team dynamics that include problem solving,communication skills, and conflict resolution.

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Key Elements of Kaizen Quality

Effort

Involvement ofemployees

Willingness to change

Communicati

on

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Kaizen Umbrella : Application of

Kaizen

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Continuous Improvement

Is the continuous elimination of waste

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Elimination of Wastes and Continuous

Improvement

Work with a versatile team

Measure, evaluate

Find the 5 Whys Follow up

Standardize, make uniform

Simplify

Combine

Prevent

Make waste ugly

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Visual Control & the Workstation

The

5 S

To Sort

Eliminate whats

not absolutely

necessary

To Sanitize

Improvement ofthe workstation.Be organized toreduce clutter.

To Straighten

Ensure space foreach thing, and athing for each space.No more searching.

To Sweep

Maintain a cleanand orderly space tomake problemseasily identifiable.Eliminate rejectsand scrap..

To Sustain

Maintain

continuous

effort. This is a

way of life.

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1. TARGET PROGRESS REPORT

2. STANDARDIZED WORK SHEET

3. TIME OBSERVATION SHEET

4. CYCLE TIME / TAKT TIME BAR CHART

5. YAMAZUMI (STACK) CHART6. STANDARDIZED WORK COMBINATION SHEET

7. CAPACITY SHEET

8. KAIZEN PROPOSAL SHEET

9. KAIZENNEWSPAPER

BASIC KAIZENTOOLS

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Results Kaizen reduces wastes.

Kaizen improves space utilization, product

quality, use ofcapital, communication,

production capacity & employees

retention.

Kaizen provides immediate results. It doesnot focus on large capital intensive

improvements.

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Kaizen focuses on creative solutions

instead of capital expenditures

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Thanks