KAIZENKAIZEN- AN INTRODUCTION

Masaaki Imai is known as the developer of Kaizen. KAI means 'change' or 'the action to correct'. ('zen') ZEN means 'good'

Definitions:
y

kaizen is small incremental changes made for improving productivity and minimizing waste. Destroy, in our minds, the concepts and techniques of manufacturing that we practice today. Create a vision of what our production system and manufacturing techniques should be. Japanese word for continuous improvement that encompasses the idea of employee participation and promotes a process-ori- ented culture

Continuous Improvement A methodical approach to continually changing and adjusting business and manufacturing processes to satisfy changes in customers expectations through the elimina- tion of nonvalueadded activities. y Cycle Time The time required to complete the tasks in a workstation or work process from start to finish.
y

Basic Rules for Change

Keep an open mind to change No such thing as a dumb question or idea Avoid spending money (Capital expense should be a last resort)

Maintain a positive attitude Dont make excuses & question current practices Think about how to do it, NOT why it cant be done Just do it!! Have Fun!!!

What is TAKT Time?

TAKT time is how many minutes or seconds are needed to make one part when considering the daily volumes, to be produced in that workcell and the total time available to perform the job.

FEATURES OF KAIZEN
y Widely
y

applicable Can be used in both manufacturing and non-manufacturing environments

Highly effective & results oriented. Kaizen events will generate quick results, Measurable results. y A Learning Experience Every member of a Kaizen Team will walk away from the event learning something new. y Team based & cross functional Team

members can be from various functions of the business. Top management participation is encouraged.

PHASES IN KAIZEN

BENEFITS OF KAIZAN
Kaizen Reduces Waste- like inventory waste, time waste, workers motion y Kaizen Improves space utilization, product quality y Results in higher employee moral and job satisfaction, and lower turn-over.
y
y

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.

ELEMENTS OF WASTE
Definition Example
1. Transportation - Carrying Tools to Point of Use

1. Transportation - Transporting farther than necessary or temporarily locating, filing, stacking and moving parts (people, paper, information) is waste. 2. Correction - Doing something over is waste. 3. Overproduction - Generating excess paper or information, or generating information or paper too soon in a process is waste.

2. Correction - Redo an Activity Because of Error 3. Overproduction - Number of Copies

ELEMENTS OF WASTE

Definition

Example
4. Motion - Tools in drawers

4. Motion - Unnecessary work movements are a form of waste.

5. Waiting - Waiting for people, 5. Waiting - Meetings to start paper and information is waste it stops work. 6. Inventory - Too much of anything is waste. 6. Inventory - Supplies

7. Processing - this is waste in 7. Processing - Typed when the process itself. Redundant handwritten would be activities sufficient

5 S in KAIZEN
y

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 Simplifying

keeping only essential items

eliminates extra motion. keep the workplace clean standardized work practices maintaining and reviewing standards

Sweeping Standardizing Sustaining

y y

PIT FALLS IN KAIZEN

y

Resistance to change Lack of proper procedure to implement Too much suggestion may lead to confusion and time wastage

Red Tag Event

y

A process improvement project in which unnecessary and unused items from business or manufacturing processes are removed. Used in conducting the first S of a 5S campaign.

Kaizen Champion An employee who is dedicated 100 percent to kaizen and to driving the continuous improvement efforts within the organization. y Kaizen Event A preplanned, scheduled process improvement project intended to implement lean manufacturing principles. Kaizen events are planned four weeks in advance to ensure 100 percent participation of team members and achievement of the event goals.
y

Kaizen Event Communication Board A visual aid used to communi- cate kaizen event information about teams, schedules, work areas, and team goals. Displayed near break rooms or facility entrances. y Kaizen Event Suggestion Box Used for collecting employee recom- mendations on future kaizen events. y Kaizen Event Tracking Worksheet A spreadsheet used by the kaizen governing committee to plan and track all kaizen events in the organization to ensure completion of all kaizen-related activities. See kaizen governing committee.
y

Kaizen Governing Committee A group of upper managers who over- see all kaizen event activities in the company. The committee, lead by the kaizen champion, meets once a month. y Kaizen Team A dedicated team of employees selected to participate in a kaizen event. Team members are selected two weeks prior to an event, and their usual dayto-day responsibilities will be given to someone else during that time.
y

Thank you