KAIZEN

Kaizen Training Basic-

 WHAT IS KAIZEN

•CONTINUOUS IMPROVEMENT

•NEW TECHNOLOGY ADAPTATION

Kaizen Training Basic-

 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.
• INVOLVES EVERY BODY & GROUP
BASED
• HUMANISTIC
• MAINTAIN & IMPROVE EXISTING
SYSTEM.
• REQUIRES NO INVESTMENT.
• EFFECT IS LONG TERM & LONG
LASTING BUT NOT OBVIOUS IN
SHORT TERM.
• CONVENTIONAL KNOW-HOW BY
WAY OF EXPERIENCE.
Kaizen Training Basic-
• SPORADIC AND IN BIG STEP
• SUDDEN.
• INVOLVES FEW . BRILIANT PEOPLE & IS
INDIVIDUAL BASED.
• TECHNOLOGY ORIENTED.
• THROWS OLD SYSTEM BRINGS NEWER
ONES.
• REQURIES HEAVY INSVESTMENT.
• DRAMATICALLY VISIBLE IN SHORT
TERM BUT IS SMALLER IN LONG TERM
• RELIES ON NEW INVENTIONS &
THEORIES.
 3-M

Kaizen Training Basic-

 3M
• MURI - INCONVENIENCE
• MUDA - WASTAGE
• MURA - INCONSISTANCY

Kaizen Training Basic-

 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-

 1M- MURI
(INCONVENIENCE)
-- HIGH SPEED WORK.

-- UNCOMFORTABLE POSITION OF OPERATOR.

-- DEPENDENCE ON PHYSICAL WORK.

-- UNNECESSARILY HIGH STANDARDS

-- LACK OF EDUCATION & TRAINING

Kaizen Training Basic-
 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-
 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-

 3-K

Kaizen Training Basic-

 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-

 4-G
Effective Problem Solving

Kaizen Training Basic-

 GENCHI : GO TO THE ACTUAL PLACE

GENBUTSU : SEE THE ACTUAL PROBLEM

GENJITSU : TAKE REALISETIC ACTION

BASE ON FACT.

GENSOKU : ACTION MUST BE BASED ON

SOUND THEORIES.

Kaizen Training Basic-

 5-S

Improve Quality

Kaizen Training Basic-

 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-

 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.

Kaizen Training Basic-

 5s(ELEMENTS)
5 SIMPLE STEPS
1. SEIRI : SORTING OUT
2. SEITON : SYSTEMATIC
ARRANGEMENT
3. SEISO : SPIC & SPAN
(CLEANUP)
4.SEIKETSU : STANDARDIZATION
5.SHITSUKE : SELF DISCIPLINE
Kaizen Training Basic-
 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-

 5s
(SEIRI) SORTING OUT, ORGANIZATION
1. CLEARLY DISTINGUISH NEEDED ITEMS
FROM UNNEEDED

OR

2. IDENTIFY USABLE & NON – USABLE ITEM

Kaizen Training Basic-

 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-

 5s
(SEITON) SYSTEMATIC ARRANGEMENT

A RATIONAL ORDERLY AND METHODICAL

ARRANGEMENT OF ALL ITEMS WE USE, RE –
WORK OR WRITE OFF.

Kaizen Training Basic-

 5s
(SEITON) SYSTEMATIC ARRANGEMENT
• PUTTING THINGS IN ORDER AFTER

• TO MINIMIZING SEARCH TIME AND ERRORS.

Kaizen Training Basic-

 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-

 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-

 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-

 5s
(SEISO) CLEAN UP
UNDERSTANDING HOW TO PREVENT THINGS
FROM GETTING DIRTY AND ENSURING TIP TOP
CONDITION.

Kaizen Training Basic-

 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-

 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-

 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-

 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-

 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-

 5s
CONCLUSION
WELL RECOGNIZED JAPANESE METHOD FOR WORK
IMPROVEMENT.
5-S CONSISTS OF FIVE PRINCIPLES:
• ORGANIZATION
• NEATNESS
• CLEANING
• STANDARDIZATION
• DISCIPLINE.

Kaizen Training Basic-

 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-

 POKA-YOKE

Kaizen Training Basic-

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-

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-

 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-
 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-

 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-
 EXACTNESS

Kaizen Training Basic-

 EXACTNESS

A MEANS OF ARRESTING VARIATIONS.

Kaizen Training Basic-

 EXACTNESS

MANAGEMENT HAS THREE KEY FUNCTIONS:

• RETAINMENT

• IMPROVEMENT

• BREAKTHROUGHS

Kaizen Training Basic-

 EXACTNESS

RETAINMENT IS BUILD ON TWO KEY FACTORS:

• EXACTNESS

• DAILY WORK MANAGEMENT.

Kaizen Training Basic-

 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-

 EXACTNESS

EXACTNESS OF OPERATION COME THROUGH EXACTNESS IN:

• MAN

• METHOD

• MATERIAL

• MACHINE

• ENVIRONMENT

Kaizen Training Basic-

 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-
 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-

 P-D-C-A

Kaizen Training Basic-

 PDCA

PLAN : THINK FUTURE AND PLAN

DO : 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-
 PDCA
DEMING CYLCLE MANAGEMENT CYCLE
(ORGANISED FOR PRODUCT LIFE CYCLE) (MODIFIED FOR GENERALUSE)

DESIGN
SALES& ACT PLAN
SERVICES

INSPECTION PRODUCTION CHECK DO

 P-D-C-A METHODOLOGY
PLAN RESULT AND THEN PROCESS
(WHAT/ EFFECT) (HOW/ CAUSE)

DO TRAIN AND THEN IMPLEMENT

CHECK : RESULT AND ALSO PROCESS

ACT : COUNTERMEASURE & OR MAINTAIN AS

(FOR RESULTS) IT IS &
PREVENTION IMPROVE
Kaizen Training Basic-
(FOR CAUSES)
 Thank you

Kaizen Training Basic-