KAIZEN

Aim

• The aim of this presentation is to introduce the Kaizen Philosophy, its principles and benefits.

Objective

• At the end of the presentation the audience should be able to apply the Kaizen principle correctly for a continuous improved performance in the execution of their assigned tasks.

Scope • Kaizen philosophy • Basic concept of Kaizen• Kaizen Approach • Steps in Kaizen• Principles of Kaizen• Theme of Kaizen• Kaizen tools • The 5 elements • Benefits of Kaizen• PDCA cycle

Introduction

• “KAIZEN” is an activity to improve productivity by recognizing the existing situation and solving the problems of the organization continuously and gradually utilizing existing management resources (man, machine, material, method and measurement).

Kaizen Philosophy

• Productivity comes from elimination of waste.

• Attack the root cause of the problem and not the symptoms.

• Involve all – from the general to the sanitary orderly.

• Acknowledge that humans are all mortals.

Basic ConceptsWhat is KAIZEN?

• The term of KAIZEN has been known as “Japanese art of continuous improvement (CI)”

• “KAIZEN” is an activity to improve productivity by recognizing the existing situation and solving the problems of the organization continuously and gradually utilizing existing management resources (man, machine, material, money and information).

Continuous improvement

• utilizes experiences and know how accumulated in the organization• introduces and utilizes various easy-to-understand management technology• is implemented by total participation• does not require a big capital investment• does not require innovative engineering technology

KAIZENKAI …..

CHANGE

ZEN ….GOOD(FOR THE BETTER)

KAIZEN…..CONTINUAL IMPROVEMENT

KAIZEN approach

• Productivity• Quality• Time• Innovation

Steps in Kaizen

• Utilizes experiences and know how accumulated in the organization

• Introduces and utilizes various easy-to-understand management technology

• Is implemented by total participation

• Does not require a big capital investment

• Does not require innovative engineering technology

•  

Steps in Kaizen

• Prepare to start - trg, tools, improvement processes

• Pilot

• Replicate

• Integrate TQM

• Start a new cycle

Principles of Kaizen

• Develop the strong point rather than remove the weak point.

• Perform management of priority by ABC analysis.

• Perform three-real ism.• Discuss what is wrong rather than who is

wrong based on the data.

Principles of Kaizen

• Use the method which even the least skilled person can do.

• Practice visual control.• Accept the failure as the result of efforts.• Think while running and run while

thinking.

Principles of Kaizen

• Consider the efficiency and effect of Kaizen.– Relation with materials– Relation with machine and equipment– Relation with method– Relation with workers– Relation with time– Relation with type of product

Theme of KAIZEN:Analyze the cause of low achievement ratio and improve it.

Gap between the target and the actual operation result

• Q: Isn’t fraction defective higher than expected?• C: Cost is competitive?• D: Aren’t there delay in delivery?• S: Labor accidents happen from time to time?• M: Absence rate is not high?• P: Does production quantity match the demand?

Theme of Kaizen cont…..• Check of P, Q, C, D, S, MMaterialMachineMethod

• Check of Material, Machine, Man, Method

Man to carry several corrugated boxes of 20kg.Means of transportation:

1. What is your most important job?(Big item oriented)

2. Is it going well?(Necessity of check)

3. How do you measure whether it goes well or not?(Necessity of measurement)

KAIZEN toolsSystematic approach means an activity based on the following points.

1. Tackle the problem systematically and from the point of entire situation of the company.

2. Utilize both inductive approach and deductive approach.

3. Utilize some simple IE (Industrial Engineering) technique and QC tools as well as basic problem solving techniques, such as 5S, to improve productivity and quality.

4. Improve competitiveness of the company by continuous activity and horizontal development.

The Five Main Elements of Kaizen

• Teamwork

• Personal discipline

• Improved morale

• Quality circles

• Suggestions for improvement

Benefits

• Elimination of waste (muda) and incorporation of efficiency

• The kaizen five - S framework for a well organized shop floor – Seiri - tidiness– Seiton - orderliness

Benefits

– Seiso - cleanliness– Seiketsu - standardized clean-up– Shitsuke - discipline

• Standardization

PDCA Cycle

PLAN

• Establish the objectives and processes necessary to deliver results in accordance with the expected output. By making the expected output the focus, it differs from other techniques in that the completeness and accuracy of the specification is also part of the improvement

DO

• Implement the new processes. Often on a small scale if possible.

CHECK

• Measure the new processes and compare the results against the expected results to ascertain any differences.

ACT

• Analyze the differences to determine their cause. Each will be part of either one or more of the P-D-C-A steps. Determine where to apply changes that will include improvement. When a pass through these four steps does not result in the need to improve, refine the scope to which PDCA is applied until there is a plan that involves improvement.

PLANPLAN

DODO ACTACT

CHECKCHECK

PLANPLAN

DODO ACTACT

CHECKCHECK

PDCA (DEMING’S) QUALITY PDCA (DEMING’S) QUALITY CYCLECYCLE

TIMETIME

IIMMPPRROOVVEEMMEENNTT

Recap