continues improvement

8/9/2019 Continues Improvement

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Gaurav Patel (65) Shravan Bhumkar (100) KishoreGulhane (74) Tushar Patil (66) Kunal Banthia(75) Rakesh DhalBisoi (89)

Mangesh Gade (23)

POM-Prof. KrishITM, Kharghar, EMBA, Batch-13, Group-


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o INTRODUCTIONo Process Management

o Process Control

o Process improvement (KAIZEN)o KAIZEN Implementation

o Benefits of KAIZEN

o EXAMPLE


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o Planning and administrating the activities necessary to

achieve high quality in business processes; and also

identifying opportunities for improving quality and

operational performance ultimately, customer satisfaction.

o

Process simplification reduces opportunities for errors andrework.

o Processes are of two types value-added processes and

support processes.

o Value-added processes those essential for running the

business and achieving and maintaining competitive

advantage. (Design process, Production/Delivery process)


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o Support processes Those that are important to an

organizations value-creation processes, employees and daily

operations.

o Value creation processes are driven by external customer

needs while support processes are driven by internal needs.o To apply the techniques of process management, a process

must be repeatable and measurable.

o Process ownersare responsible for process performance and

should have authority to manage the process. Owners could

range from high-level executive to workers who run a cell.

o Assigning owners ensures accountability.


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o Control is the activity of ensuring the conformanceto the requirements and taking corrective actionwhen necessary.

o Two reasons for controlling the process

1. Process control methods are the basis ofeffective dailymanagement of processes.

2. Long-term improvementscan not be made to a processunless the process is first brought under control.

o Short-term corrective action should be taken by the

process owners. Long-term remedial action shouldbe the responsibility of the management.


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o Japanese for gradual and orderly continuousimprovement over a long period of time with minimumfinancial investment, and with participation by everyonein the organization.

o It is also a process that, when done correctly, humanizes

the workplace, eliminates overly hard work, and teaches

people how to perform experiments on their work using

the scientific method and how to learn to spot and

eliminate waste in business processes.

o Improvement in all areas of business serves to enhancequality of the firm.


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o The five foundation elements of Kaizen

o Teamwork

o Personal discipline

o Improved morale

o Quality circles

o Suggestions for improvement


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JapaneseTerms

EnglishTranslations

5S Terms Definitions

Seiri Tidiness SORT Throw away rubbish andunrelated materials.

Seiton Orderliness SET IN ORDER Set things in proper placefor quick retrieval/ storage.

Seiso Cleanliness SHINE Clean the workplace.

Everyone should be ajanitor.

Seiketsu Standardization STANDARDIZE Standardize the way ofmaintaining cleanliness.

Shitsuke Discipline SUSTAIN Make it a way of life. This

means commitment.


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Implement the new

processes on trial basis.

Data collected and

documented.

Measure the new processes and

compare the results against the

expected results to ascertain any

differences.

Analyze the differences

to determine their cause.

Revised plan

implementation.

Establish the objectives and

processes necessary to

deliver results in

accordance with the

expected output.

PDCA Cycle or PDCA Wheel


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o Kaizen Reduces Wastein areas such as inventory, waitingtimes, transportation, worker motion, employee skills, over

production, excess quality and in processes.

o Kaizen Improvesspace utilization, product quality, use of

capital, communications, production capacity andemployee retention.

o Kaizen Providesimmediate results. Instead of focusing on

large, capital intensive improvements, Kaizen focuses on

creative investments that continually solve large numbersof small problems. Large, capital projects and major

changes will still be needed, and Kaizen will also improve

the capital projects process, but the real power of Kaizen is

in the on-going process of continually making small

improvements that improve processes and reduce waste.


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Example -1


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Orange Packing 2


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Hero Honda Silencer Internal Assembly


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continues improvement

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