KAIZEN

2

AGENDA

Introduction Introduction: Man Behind Kaizen Introduction: Who does Kaizen? Why ?

Kaizen Methodology Gemba Kaizen

1. Housekeeping 2. Muda elimination 3. Standardization

Toyota Example Summary/Benefits of Kaizen

3

INTRODUCTION: MAN BEHIND KAIZEN

Masaaki Imai is known as the developer of Kaizen. He is known as the “Lean Guru” and the father of Continuous Improvement

According to him In simple words Kaizen means improvement. Kaizen strategy calls for never-ending efforts for improvement involving everyone in the organization – managers and workers alike.

Author of books like Kaizen(1986)Key to Japans Competitive success and Gemba Kaizen(1997)

http://en.wikipedia.org/wiki/Masaaki_Imai

4

INTRODUCTION: WHO DOES KAIZEN ? WHY ?

WHY ? Maintenance

Objective of the maintenance function is to maintain current technological, managerial, and operating standards

Innovation Improvement function is aimed

at improving current standards.

WHO ? Kaizen

- Ongoing improvement involves everyone Top management Managers Workers

http://www.kaizen.com/

5

KAIZEN METHODOLOGY

Finding out the pain area

Analysis of the pain area

3M‘s Considered with the 4M‘s

3M’s MURA, MURI, MUDA muda ("non-value-adding work") muri ("overburden") mura ("unevenness")

4M’s MAN, MACHINE, MATERIAL, METHOD

http://en.wikipedia.org/wiki/Kaizen

6

TYPES OF WASTES

•Mura(Unevenness) is avoided through Just In Time systems which are based on little or no inventory, by supplying the production process with the right part, at the right time, in the right amount

MURA

•Muri(overburden) can be avoided through standardized work. To achieve this a standard condition or output must be defined to assure effective judgment of quality.

MURI

•Muda(non-value-adding work) Can be avoided by identifying and eliminating non value adding and unnecessary activitiesMUDA

http://en.wikipedia.org/wiki/Lean_manufacturing#Types_of_waste

7

GEMBA KAIZEN Gemba is a Japanese word meaning 'real place,'

where the real action takes place. In business, Gemba is the ‘shop floor’ or ‘production place’ where the value-adding activities to satisfy the customer are carried out.

3 Ground rules for practicing Kaizen in Gemba are: - 1. Housekeeping, 2. Muda elimination. 3. Standardization.

http://www.gemba.com/

8

1. HOUSEKEEPING

http://www.gemba.com/

5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized.

To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following "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

9

2. MUDA ELIMINATION

http://www.gemba.com/

10

3. STANDARDIZATION

Standards may be defined as the best way to do the job

Products or services are created as a result of a series of processes. Certain standard must be maintained at each process in order to assure quality.

Standards also can prevent recurrence of the same problem

http://www.gemba.com/

11

TOYOTA EXAMPLE

Management Philosophy

Respect for People & Continuous Improvement

The success of the Toyota Production System can be attributed to Eliminating wasted time and

resources Building quality into

workplace systems Finding low-cost but reliable

alternatives to expensive new technology

Perfecting business processes

Building a learning culture for continuous improvement

Source : The Toyota Way, Jeffrey K. Liker 

12

BENEFITS OF KAIZEN Kaizen Reduces Waste like

inventory waste, time waste, workers motion

Kaizen Improves space utilization, product quality

Results in higher employee moral and job satisfaction, and lower turn-over.

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.

http://en.wikipedia.org/wiki/Kaizen

13

QU

ES

TIO

NS

PLEA

SE !

THANK YOU !

Q & A TIME !