japanese and other productivity techniques in manufacturing
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JAPANESEANDOTHERPRODUCTIVITY
TECHNIQUESINMANUFACTURING
Kaizen, JIT, Kanban and Poka- Yoke
Submitted to- Prof. Ajit Kurvey
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INDEX
Introduction
Management- Improvement Function
KaizenJIT
Kanban
Poka-yokeBibliography
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INTRODUCTION
Japanese manufacturing techniques generally approach
productivity with the goal of reducing unnecessary
expenses, waste and time, while increasing production
and efficiency.
Many of the modern Japanese manufacturing techniques
were developed after World War II and peaked in the
1980s.
Large companies such as Toyota are credited with
pioneering many of the manufacturing techniques used
by Japanese companies and these techniques have spread
to non-Japanese companies as well, due to their
effectiveness
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IMPROVEMENTFUNCTION- KAIZEN
Kaizen: The Key to Japan's Competitive Success
This method became famous by the book of Masaaki
Imai which meansKAIChange & ZENGood i.e
improvement.
It means works continuously towards revising the
current standards, once they have been mastered, and
establishing higher ones.
Improvement can be broken down between innovation
and Kaizen.
Kaizen signifies small improvements as a result of
coordinated continuous efforts by all employees.
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IMPROVEMENTFUNCTIONKAIZEN(CONTD...) By improving standardized activities and processes,
kaizen aims to eliminate waste as in leanmanufacturing( Toyota Production System )
Kaizen was first implemented in several Japanese
businesses after World War II, influenced in part by
American business and quality management teacherswho visited the country
It is also a process that, when done correctly,
humanizes the workplace, eliminates overly hard work,
and teaches people how to perform experiments ontheir work using the scientific method and how to learn
to spot and eliminate waste in business processes.
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KEYPRACTICES
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Customer Orientat ion Determine the perceptions, needs, and wants of target markets
Satisfy them through the design, communication, pricing
Quali ty Contro l Circ le (QCC) Come together to discuss with the management issues related to either quality
control or improvement in production methods.
Voluntarily meet on a regular basis to identify, analyze and solve their problems.
Disc ip l ine in the work place
Co-operative Labo r Manager Relations . TQM
Functions on the premise that the quality of the products andprocesses is the responsibility of everyone who is involved withthe creation or consumption of the products or services offered bythe organization.
Quali ty Improvement
It is a formal approach to the analysis of performance andsystematic efforts to improve it. There are numerous models used.Some commonly discussed include: PDSA , Six Sigma , CQI,TQM
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Autom at ion and Robot ics
Autonomat ion
Itis
automationwith a human touch
.
If there is a problem the machine can not resolve , the
production is stopped and the human workers look into the
matter and apply countermeasures so that such things do not
happen again .
Kanban Jus t-in-t ime
Zero defects
It tries to bring defects in production to zero .
Total Produ ctive Maintenance the machine operator is thoroughly trained to perform much of
the simple maintenance and fault-finding.
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KAIZENATTOYOTA
There are two kinds of kaizen activities at Toyota:
kaizen made by the supervisory staff and engineers astheir functions,
that made by workers through the quality circles and
suggestion system.
Cost of each of the parts and a standard time for theirproduction.
A maintenance team
An assembly line is divided into about ten segments per
function
A large conveyer installed on the ground level permit
workers to operate
Tasks to carry heavy parts also disappeared by installing
automatic or semi-automatic equipment .
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FEATURESOFKAIZEN
Improvements are based on many small changes
Small improvements are less likely to require major
capital investment.
The ideas come from the talents of the existing
workforce
Continuous improvement in individual performance
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FEATURESOFKAIZEN( CONTD...)
It helps encourage workers, thereby improvingworker motivation
Kaizen is a daily process, the purpose of which
goes beyond simple productivity improvement.
humanizes the workplace, eliminates overly hardwork ("muri"),
Teaches people how to perform experiments ontheir work using the scientific method and how tolearn to spot and eliminate waste in businessprocesses.
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COMPANIESIMPLEMENTINGKAIZEN
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Jit is a strategy used in inventory management.
With JIT strategy companies aim to decrease waste and inventory
costs by receiving goods only when they are needed to produce.JIT inventory mgmt thus increases efficiency and is used by companies
that prefer to keep low inventory levels.
In order for JIT to work corrctly the company must be able to predict
demand for the product and how much inventory will be needed at what
stagesIt has also been described as an approach with the objective of producing
the right part in the right place at the right time.
.
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KEY ELEMENTS OF JIT.
Reduce or eliminate setup times.
Reduce lot sizes.
Reduce lead times.Preventive maintenence.
Flexible workforce.
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ADVANTAGES OF JIT.Lower stock holding means a reduction in storage space which
saves rent and insurance costs As stock is only obtained when it is needed,
working capital is tied up in stock
There is less likelihood of stock perishing ,becoming obsolete or
out of date. Avoids the build-up of unsold finished product that can occur
with sudden changes in demand
Less time is spent on checking and re-working the product
of others as the emphasis is on getting the work right first time
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DISADVANTAGES OF JIT.
There is little room for mistakes as minimal stock is kept for
re-working faulty product
Production is very reliant on suppliers and if stock is
not delivered on time, the whole production schedule can be delayed.
There is no spare finished product available to meet unexpected orders,
because all product is made to meet actual orders
however, JIT is a very responsive method of production
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IMPROVEMENTFUNCTIONKANBAN
Kanban (literally signboard or billboard) is a
scheduling system for lean and just-in-time (JIT)
production. According to its creator, Taiichi Ohno,
kanban is one means through which JIT is achieved
It is a inventory scheduling system that helps
determine what to produce, when to produce it, and
how much to produce
The need to maintain a high rate of improvement
led Toyota to devise the kanban system. Kanbanbecame an effective tool to support the running of
the production system as a whole.
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IMPROVEMENTFUNCTION
KANBAN(CONTD...)
Basic Principles:-
Start with what you do now
Agree to pursue incremental, evolutionary change
Respect the current process, roles, responsibilities &
titles
Leadership at all levels
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IMPROVEMENTFUNCTION
KANBAN(CONTD...)
Kanban cards
Three bin System
Electronic systems
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POKAYOKE
Japanese for mistake-proofingPoka - inadvertent mistake
Yokeprevent
Developed in the 1960s
Either prevents a mistake from
being made or makes the mistakeobvious at a glance
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The cause of defects lie in worker errors, and defects are a
result of neglecting those errorsmistakes will not turn
into defects if worker errors are discovered and eliminated
beforehand - Shingo
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THREETYPESOFINSPECTION
Judgment inspection
Informative inspection
Source inspectionOften Poka Yoke devices
ensure the proper operatingconditions exist prior to actualproduction
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POKAYOKEDEVICECATEGORIES
Prevention device - makeerrors impossible
Detection device - Makeerrors visible to the operator
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CHARACTERISTICSOFGOODPOKAYOKEDEVICES
they are simple and cheapthey are part of the process
they are placed close towhere the mistakes occur
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