PREPARED BY ::Pinky Gandhi , Satyajit Gaekwad ,Mukesh Ghadavi , Manish Jani

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

Applicability of Kaizen .

. ‡ Kaizen must be approached in such a way that no one is blamed and that the best process is put into place. ‡ Kaizen has three main principles: ‡ Consider the process and the results! ‡ The need to look at the entire process of the job at hand and to evaluate the job as to the best way to get the job done.‡ So basically kaizen is small incremental changes made for improving productivity and minimizing waste.

and measure the change!!! A Learning Experience ± Every member of a Kaizen Team will walk away from the event learning something new! ! Team based & cross functional ± ‡ ‡ ‡ Team members can be from various functions of the business.FEATURES OF KAIZEN ‡ Widely applicable ± Can be used in both manufacturing and nonmanufacturing environments Highly effective & results oriented. . Kaizen events will generate quick results. Measurable results. Establish the baseline. Top management participation is encouraged.


) Plan an Event C.) Select an Event B.) Implement an Event D.) Follow-up to an Event .THESE STEPS ARE SHORTEN INTO : A.

workers motion ‡ Kaizen Improves space utilization. of which 99% were implemented. .S.000 inventory waste. plant. ‡ Toyota is well-known as one of the leaders in using Kaizen. 7. and lower turn-over. time waste. In 1999 at one U.BENEFITS OF KAIZAN ‡ Kaizen Reduces Waste. product quality ‡ Results in higher employee moral and job satisfaction.000 Toyota employees submitted over 75.

Varieties of Kaizen Methods ‡ Individual Versus Teamed ‡ Day-to-Day Versus Special Event ‡ Process Level Versus Sub process Level .

keep the workplace clean standardized work practices maintaining and reviewing standards ‡ ‡ ‡ Sweeping Standardizing Sustaining . especially a shared workplace (like a shop floor or an office space). To take the concept of Kaizen performance to its ultimate level of simplicity.5 µS¶ in KAIZEN ‡ 5S is a method for organizing a workplace. and keeping it organized. it offered the following "5S" steps ‡ ‡ ‡ Sorting Simplifying keeping only essential items eliminates extra motion.

PIT FALLS IN KAIZEN ‡ Resistance to change ‡ Lack of proper procedure to implement ‡ Too much suggestion may lead to confusion and time wastage .

Examples of Kaizen .

Before and After .

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