KAIZEN
Kaizen Training Basic-
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WHAT IS KAIZEN
•CONTINUOUS IMPROVEMENT
•NEW TECHNOLOGY ADAPTATION
Kaizen Training Basic-
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KAIZEN
These improvement were made by involving all employees hence their
Morale, Productivity and Quality went up, resulting in cost reduction
Whenever any new technologies were introduce, the changeover was
Very smooth. This approach is Called KAIZEN
KAIZEN Vs INNOVATION
• CONTINUOUS AND IS IN SMALL
STEPS
• GRADUAL.
• SPORADIC AND IN BIG STEP
• INVOLVES EVERY BODY & GROUP
BASED
• HUMANISTIC
• MAINTAIN & IMPROVE EXISTING
SYSTEM.
• REQUIRES NO INVESTMENT.
• INVOLVES FEW . BRILIANT PEOPLE & IS
INDIVIDUAL BASED.
• SUDDEN.
• TECHNOLOGY ORIENTED.
• THROWS OLD SYSTEM BRINGS NEWER
ONES.
• REQURIES HEAVY INSVESTMENT.
• EFFECT IS LONG TERM & LONG
LASTING BUT NOT OBVIOUS IN
SHORT TERM.
• CONVENTIONAL KNOW-HOW BY
WAY OF EXPERIENCE.
Kaizen Training Basic-
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• DRAMATICALLY VISIBLE IN SHORT TERM
BUT IS SMALLER IN LONG TERM
• RELIES ON NEW INVENTIONS &
THEORIES.
3-M
Kaizen Training Basic-
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3M
• MURI
• MUDA
• MURA
Kaizen Training Basic-
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- INCONVENIENCE
- WASTAGE
- INCONSISTANCY
3M OBJECTIVE
BASIC OBJECTIVE OF QUALITY CONTROL IS TO
AVOID THESE 3M IN PRODUCTION PROCESS. BY
IMPROVING.
--- METHOD OF WORK.
--- MACHINE LAYOUT
--- HUMAN RELATIONSHIP
Kaizen Training Basic-
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1M- MURI
(INCONVENIENCE)
-- HIGH SPEED WORK.
-- UNCOMFORTABLE POSITION OF OPERATOR.
-- DEPENDENCE ON PHYSICAL WORK.
-- UNNECESSARILY HIGH STANDARDS
-- LACK OF EDUCATION & TRAINING
Kaizen Training Basic-
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2M-MUDA
(WASTAGE)
-- TIME WASTAGE BY WORKERS.
-- UNNECESSARY MOVEMENT IN THE PROCESS OF
MATERIALS AS WELL AS MEN.
-- SCRAP.
-- REJECTED MATERIAL.
-- HANDLING
-- IMPROPER PLANNING
-- IMPROPER MAINTENANCE OF MACHINE.
Kaizen Training Basic-
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3M-MURA
(INCONSISTENCY)
-- SOME WORKER WORK HARD AND OTHER DO NOT.
-- INCONSISTENT QUALITY OF PARTS
-- MACHINES ARE INCONSISTENT.
-- LINES ARE NOT BALANCED
Kaizen Training Basic-
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3-K
Kaizen Training Basic-
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3-K
Way to standardize the work and minimize mistake
KIMERAARETA KOTA GA : WHAT HAS BEEN DECIDED
KIHON DORI
: EXAXTLY AS PER STANDARD
KICHIN TO MAMORU
: MUST BE FOLLOWED
Kaizen Training Basic-
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4-G
Effective Problem Solving
Kaizen Training Basic-
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GENCHI
: GO
GENBUTSU
: SEE THE ACTUAL PROBLEM
GENJITSU
: TAKE REALISETIC ACTION
BASE ON FACT.
GENSOKU
: ACTION MUST BE BASED ON
SOUND THEORIES.
Kaizen Training Basic-
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TO THE ACTUAL PLACE
5-S
Improve Quality
Kaizen Training Basic-
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WHAT IS WORK PLACE
ORGANIZATION
A SYSTEMATIC & RATIONAL APPROACH TO
CLUTTER FREE, SAFE, WORKPLACE WITH THE
OBJECTIVE OF REDUCING WASTE & PREPARING
THE GROUND FOR FURTHER IMPROVEMENT.
Kaizen Training Basic-
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5s (BACKGROUND)
SINCE THE EARLY 80`S JAPANES INDUSTRIES
WIDELY PRACTICED 5S AS A POWERFUL
TECHNIQUE AND QUALITY .
TODAY 5S IS USED IN WORLDWIDE TO PREPARE
THE GROUND FOR IMPROVEMENT.
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5s(ELEMENTS)
5 SIMPLE STEPS
1. SEIRI
2. SEITON
3. SEISO
4.SEIKETSU
5.SHITSUKE
Kaizen Training Basic-
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: SORTING OUT
: SYSTEMATIC
ARRANGEMENT
: SPIC & SPAN
(CLEANUP)
: STANDARDIZATION
: SELF DISCIPLINE
5s
(SEIRI) SORTING OUT, ORGANIZATION
HUMAN TENDENCY OF NOT THROWING AWAY THINGS, BECAUSE WE
THINK “ IT MIGHT COME IN HANDY SOME DAY” HOWEVER IN MOST CASE ,
WHEN YOU NEED THEM THEY ARE EITHER NOT TRACEABLE OR HAVE
DETERIORATED BEYOND USE.
SEIRI IS ABOUT SEPARATING THINGS WHICH IS NECESSARY FOR JOB FROM
THOSE THAT ARE NOT & KEEPING THE NECESSARY ONCE.
Kaizen Training Basic-
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5s
(SEIRI) SORTING OUT, ORGANIZATION
1. CLEARLY DISTINGUISH NEEDED ITEMS
FROM UNNEEDED
OR
2. IDENTIFY USABLE & NON – USABLE ITEM
Kaizen Training Basic-
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5s
(SEIRI) SORTING OUT, ORGANIZATION
HELPS TO :
• DECREASE UNNECESSARY ITEMS / RESERVE STOCK.
EFFECTIVE SPACE UTILIZATION
• STOP MATERIALS FROM DETERIORATING AND / OR
GETTING DAMAGE
• REDUCE WASTAGES, INCLUDING SEARCHING
TIME.
Kaizen Training Basic-
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5s
(SEITON) SYSTEMATIC ARRANGEMENT
A RATIONAL ORDERLY AND METHODICAL
ARRANGEMENT OF ALL ITEMS WE USE, RE –
WORK OR WRITE OFF.
Kaizen Training Basic-
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5s
(SEITON) SYSTEMATIC ARRANGEMENT
• PUTTING THINGS IN ORDER AFTER
• TO MINIMIZING SEARCH TIME AND ERRORS.
Kaizen Training Basic-
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5s
(SEITON) SYSTEMATIC ARRANGEMENT
STEPS:
•
•
ENSURE RATIONAL LAYOUT OF MACHINES, EQUIPMENTS
CABINETS.
PLACES FREQUENTLY-USED ITEMS AT THE POINT OF USE.
•
IDENTIFY EVERYTHING ,USE LABELS,COLOUR CODE
•
USE INDEXING FOR FILES RECORDS , DRAWINGS.
•
EASY RETRIEVABILITY.CABINET , SHELVES , RACK
•
SELF EXPLANATORY IDENTIFICATION AIDS.
•
VISUALIZATION OF EACH THINGS TO MINIMIZING SEARCH TIME AND ERRORS.
Kaizen Training Basic-
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5s
(SEITON) SYSTEMATIC ARRANGEMENT
HELP TO REDUCE:
• PREPARATION AND MACHINE SETTING
TIMINGS.
• TIME SPENT ON LOCATING OR WAITING FOR
TOOLS PARTS / MATERIALS.
• PROCESSING TIME AND CYCLE TIME ,BY
IMPROVING THE LAYOUT OF THE WORK
PLACE.
Kaizen Training Basic-
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5s
(SEISO) CLEAN UP
TO RETURN ITEMS AND PLACES USED DURING
WORK ,TO THEIR ORIGINAL CLEAN AND
POLISHED CONDITION; AS WELL AS, DISPOSAL
OF SCRAP AND LEFT –OVER MATERIALS,
THUS PURIFYING.
CLEANING BRINGS FRESHNESS, PROMOTES
ORDERLY ENVIRONMENT, AND ON ORDERLY
MIND.
Kaizen Training Basic-
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5s
(SEISO) CLEAN UP
UNDERSTANDING HOW TO PREVENT THINGS
FROM GETTING DIRTY AND ENSURING TIP TOP
CONDITION.
Kaizen Training Basic-
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5s
(SEISO) CLEAN UP
STEPS:
•
SURVEY OF THE ORIGINS OF GRIME AND LEAKAGE.
•
PRIORITIES FOR CLEANING WHERE GRIME IS MOST.
•
STUDY WHY THINGS ARE DIRTY.
•
STUDY POSSIBLE PLAN OF ACTION.
•
DECIDE ON ACTION STEPS/ RESPONSIBILITY TIME
FRAME.
Kaizen Training Basic-
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5s
(SEISO) CLEAN UP
HELP TO:
•
INCREASING ACTUAL PRODUCTION, IMPROVED
YIELDS.
•
REDUCED ACCIDENT BY REDUCING / ELIMINATING:
BREAKDOWNS.
STEP AND ADJUSTMENT TIME.
FREQUENT STOPPAGES
PROCESS DEFECTS.
Kaizen Training Basic-
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5s
(SEIKETSU) STANDARADISATION
IT EXIST WHEN FIRST THREE PILLARS SORT
SET-IN-ORDER AND SHINE ARE PROPERLY
MAINTAINED
MAKING SORT, SET-IN-ORDER AND SHINE A HABIT.
Kaizen Training Basic-
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5s
(SEIKETSU) STANDARADISATION
STEPS ARE:
•
FIX RESPONSIBILITY FOR IMPLEMENTING AND
EVALUATING SYSTEM.
•
INTEGRATE THESE RESPONSIBILITY INTO ROUTINE
WORK.
•
CHECK HOW WELL THE SYSTEM IS WORKING AND
SUSTAINING ITSELF.
Kaizen Training Basic-
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5s
(SHITSUKE) SELF DISCIPLINE,
SUSTAIN, PROPER ATTITUDE.
INSTILLING THE ABILITY TO DO THINGS THE
WAY THEY ARE SUPPOSED TO BE DONE , WITH
REGARDS TO SAFETY RULES , PRACTICES AND
PUNCTUALITY.
EMPHASIS ON CREATING A WORKPLACE WITH
GOOD WORKING HABITS.
Kaizen Training Basic-
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5s
CONCLUSION
WELL RECOGNIZED JAPANESE METHOD FOR WORK
IMPROVEMENT.
5-S CONSISTS OF FIVE PRINCIPLES:
• ORGANIZATION
• NEATNESS
• CLEANING
• STANDARDIZATION
• DISCIPLINE.
Kaizen Training Basic-
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5s
CONCLUSION
5-S WORK PLACE IS:
•
•
•
•
•
•
•
HIGH IN QUALITY
PRODUCTIVITY,
KEEPS COST DOWN,
ENSURE ON TIME DELIVERY,
SAFE TO PEOPLE TO WORK
MORALE IS HIGH
IT IS ALSO THE STARING POINT FOR MANY COMMON
QUALITY INITIATIVES SUCH AS QC CIRCLE, ISO-9000
AND TQM.
Kaizen Training Basic-
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POKA-YOKE
Kaizen Training Basic-
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POKA-YOKE (MISTAKE PROOFING)
JAPANESE WORD FOR MISTAKE PROOFING.
IS AVERY POWERFUL SET OF TECHNIQUE THAT
EITHER KEEPS DEFECTS FROM NOT OCCURRING
OR INDICATING IMMEDIATELY WHEN A DEFECT
DOES OCCUR.
Kaizen Training Basic-
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POKA-YOKE (MISTAKE PROOFING)
THE CONCEPT IS SIMPLE IF MISTAKE ARE NOT
PERMITTED TO ENTER THE PRODUCTION LINE,
THEN QUALITY WILL BE HIGH AND REWORK
LOW. THIS RESULT IN INCREASE CUSTOMER
SATISFACTION AND LOWER COST AT THE SAME
TIME THE RESULT IN HIGH CUSTOMER PERCEIVED
VALUE.
Kaizen Training Basic-
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POKA-YOKE
STEPS:
•
WHAT IS WRONG?
•
WHERE WAS DEFECT DISCOVERED?
•
WHERE WAS THE DEFECT MADE?
•
WHAT IS THE DIFFERENCE IN TIME AND DISTANCE?
•
WHAT WAS SUPPOSED TO HAPPEN?
•
WHAT HAPPENED THAT WAS NOT SUPPOSED TO
HAPPEN?
WHY DID THE MISTAKE (NON STANDARD
ELEMENT)HAPPENED?
•
Kaizen Training Basic-
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POKA-YOKE
STEPS:
•
HOW CAN EACH NON STANDARD ELEMENT
(MISTAKE) BE ELIMINATED?
•
NOW ORGANIZE FOR IMPLEMENTING THE
SELECTED POKA-YOKE. AFTER INSTALLING,
TEST OUT AND NOTE THE RESULT . ARRANGE FOR
PROPER MAINTENANCE.
Kaizen Training Basic-
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POKA-YOKE
CONCLUSION:
•
INCORPORATE QUALITY INTO THE PROCESS.
•
MISTAKE AND DEFECTS CAN BE ELIMINATED.
•
DON’T HESITATE TO GO AHEAD WITH GOOD
IDEAS AND IF AND IDEA DOESN’T WORK,
DISCARD IT IMMEDIATELY.
•
INSTEAD OF MAKING EXCUSES THINK OF WAY
TO DEAL WITH PROBLEM
•
WISDOM OF 10 IS BETTER THAN THE INSPIRATION
OF ONE
•
SEEKING THE TRUE CAUSE – 5WHYS AND 1 HOW.
Kaizen Training Basic-
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EXACTNESS
Kaizen Training Basic-
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EXACTNESS
A MEANS OF ARRESTING VARIATIONS.
Kaizen Training Basic-
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EXACTNESS
MANAGEMENT HAS THREE KEY FUNCTIONS:
•
RETAINMENT
•
IMPROVEMENT
•
BREAKTHROUGHS
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EXACTNESS
RETAINMENT IS BUILD ON TWO KEY FACTORS:
•
EXACTNESS
•
DAILY WORK MANAGEMENT.
Kaizen Training Basic-
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EXACTNESS
TO BECOME WORLD CLASS IS LAID IN UNDERSTANDING AND
IMPLEMENTING EXACTNESS.
PROF TSUDA USED TERM EXACTNESS TO SIMPLIFIES ‘EXACT’ FOR THE
PURPOSE OR EFFECTIVENESS TO IMPROVE CONFIDENCE IN OUR
PRODUCT QUALITY i.e. MEETING CUSTOMER REQUIREMENTS.
Kaizen Training Basic-
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EXACTNESS
EXACTNESS OF OPERATION COME THROUGH EXACTNESS IN:
•
MAN
•
METHOD
•
MATERIAL
•
MACHINE
•
ENVIRONMENT
Kaizen Training Basic-
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EXACTNESS
ELEMENT CONTRIBUTE TO EXACTNESS:
•
MACHINE CONDITION
•
MACHINE SET UP AND CHANGE OVER.
•
TOOL SETTING AND MONITORING CONDITION.
•
EXACTNESS OF INPUT MATERIAL
•
MATERIAL FEEDING
•
ACCESSIBILITY OF TOOLS AND CONSUMABLES
•
APPROPRIATE INFORMATION
•
APPROPRIATENESS OF HANDLING
•
EXACTNESS IN CHECKING
Kaizen Training Basic-
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EXACTNESS
ELEMENT CONTRIBUTE TO EXACTNESS:
•
MEASUREMENT
•
FEEDBACK GIVEN TO EACH WORK STATION
•
SPC
•
METHOD OF MAINTENANCE
•
SKILL LEVEL OF OPERATOR
•
COMMUNICATION ON WORK STATION / LINE.
•
SAFETY OF OPERATOR
•
HOUSEKEEPING.
Kaizen Training Basic-
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P-D-C-A
Kaizen Training Basic-
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PDCA
PLAN
DO
: THINK FUTURE AND PLAN
: ORGANIZE ALL RESOURCES TO
REALIZE THE GOAL OF PLAN
CHECK : CHECK THE RESULT , COMPARING
THE GOAL OF PLAN AND ACTUAL
ACT
: TAKE COUNTERMEASURE AND
PREVENTION
NEXT PLAN
Kaizen Training Basic-
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PDCA
DEMING CYLCLE
MANAGEMENT CYCLE
(ORGANISED FOR PRODUCT LIFE CYCLE)
(MODIFIED FOR GENERALUSE)
SALES&
SERVICES
INSPECTION
DESIGN
ACT
PRODUCTION
CHECK
PLAN
DO
P-D-C-A METHODOLOGY
PLAN
RESULT
AND THEN
(WHAT/ EFFECT)
PROCESS
(HOW/ CAUSE)
DO
TRAIN
AND THEN
IMPLEMENT
CHECK
: RESULT
AND ALSO
PROCESS
ACT
: COUNTERMEASURE &
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(FOR RESULTS)
PREVENTION
(FOR CAUSES)
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OR
MAINTAIN AS
IT IS &
IMPROVE
Thank you
Kaizen Training Basic-
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