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KAIZEN

(Project report)

Prepared By :-manmeet malik

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What is Kaizen

Kai means change or modify

zen means make good (make better)

KAI + ZEN = Change for better

Kaizen was created in Japan following World War II

Example Toyota production system.

Change means incremental, orderly and continualimprovement.

The Japanese way encourages small improvements day

after day, continuously.

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Kaizen and Muda

Kaizen aims to eliminate waste

Waste

Overproduction

Underproduction Delays (waiting time)

Unnecessary movements

Transportation loss

Defective products Misused resources

Etc.

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5 main elements of Kaizen

Teamwork Use small teams to optimize individual process

performance by implementing Incremental changes.

Everyone contributes CEO to assembly line workers,

even an external stakeholder.

Individual Discipline Punctuality, active participation, growth attitude,

strategically aligned.

Improved Morale Energized leaders with clear vision, clear communication,

transparency, motivation, training & development.

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5 main elements of Kaizen

Quality Control Circles Employee participation program. A quality control circle

consists of a group of employees (generally volunteers)

who meet periodically to identify strengths and

weaknesses in the production process. They focus on cost, security & productivity.

Suggestions for improvement Management should make every effort to help the workers

provide suggestions. For example, Toyota is well-knownas 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.

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Kaizen Stages

1. Establish a plan to change whatever needs to be

improved.

2. Carrying out changes on a small scale

3. Observe the results

4. Evaluate both the results and the process to

understand the learning.

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Applicability of Kaizen

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Tools and techniques used..

Just-in-time

Five S

Quality Circles

Zero defects

Etc.

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5 s

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 ofsimplicity, 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

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Features at a glance

KAIZEN

1. Effect Long-term and long-lasting

2. Pace Small steps

3. Timeframe Continual and incremental

4. Change Gradual and constant

5. Involvement Everybody

6. ApproachCollectivism, group efforts, systems

approach

7. Mode Continual Improvement

8. Practical requirementsRequires little investment but great

efforts to maintain it.

9. Advantage Works well in slow-growth economy

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Immediate Benefits / Results

Kaizen Reduces Waste in areas such as inventory,

waiting times, transportation, employee skills,

overproduction etc.

Kaizen Improves space utilization, product quality, use

of capital, communications, production capacity andemployee retention.

Kaizen Provides immediate results. Instead of

focusing on large, capital intensive improvements,

Kaizen focuses on creative investments that continuallysolve large numbers of small problems.

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Thanks