Presentation

Examples of KAIZEN

Suggestion system for improvement,

together with
small group activities
as one of the major features
Of
KAIZEN

Project
j
on Dissemination of
Quality/Productivity Improvement
((KAIZEN)) Practice
for Small and Medium Enterprises
in the Hashemite Kingdom
g
of Jordan
SEKI Takaharu
Japan International Cooperation Agency

Companys major reform/restructure

vs KAIZEN approach
vs.

CONTENTS

Major reform/ restructure

Research Institute Corp.

KAIZEN activities

Organized plan, evaluation

& implementation

1. Companys major reform/restructure vs.

KAIZEN approach
2. Features and benefits of KAIZEN
practices
3 Some examples of KAIZEN practices
3.
4. Suggestion system for improvement
5. Small group discussions
6. Outcomes of KAIZEN approach

Proposal derived from

daily operational scene

Official approval
for implementation

Proposal and implementation

on self initiative

Must produce
good result
Reform/ restructure
3

Implementation is
important
combined

Small improvement
found only by the
employees on the spot
4

Research

Institute Corp.

Features and benefits

of Approach

KAIZEN practice starts with small

improvement

Features:
1 Bottom up activity
1.
(Involvement of employees at the operational level)
2. Continuous efforts of the employees to improve their workplaces with
self initiative
self-initiative
Benefits:
Not only quality improvement and productivity improvement
But also provide motivation to workers for their skill up
Since,
1 The employee proposes ones
1.
one s ideas for work improvement of their
own work place, and the idea is accepted by his boss.
2. The small group discussion produces outputs
Th
Then,
the
h employee
l
fi
finds
d satisfaction,
i f i
and
d motivated
i
d to work
k ffor
improvement
Research Institute Corp.

Example (1)
Secure the eyesight to prevent collision
each other => Productivity improvement

Picking
g work at distribution Center
Factory
yB

Factory C

Plain view of the parts storage

area of a warehouse
A picking cart
ShelfParts Storage)

ShelfParts Storage)

Distribution Center

Picking Lane

Picking Lane

Picking and Delivering

materials to each shop

ShelfParts Storage)
Picking Lane
ShelfParts Storage)

Shop P

Shop Q

Shop R

Picking Lane

Main Lane

Factory
yA

ShelfParts Storage)
Picking Lane
ShelfParts Storage)
Picking Lane

Research Institute Corp.

Improvement efficiency of parts

picking works at the warehouse

KAIZEN practice starts with small

improvement

1. Carts are used at the parts storage area to pick up the

p
from the shelves.
necessaryy parts
2. The collision of two picking carts were often happened
when they go out from part storage picking lane to the main
l
lane,
resulted
lt d iin d
decrease iin work
k efficiency.
ffi i
3. There was a suggestion from a worker engaged in the
picking work to ensure eyesight by leaving the shelf without
storing parts.
4. The collisions were decreased with implementing
p
g this
suggestion.
5. This kind suggestion is possible only by the workers who
know the work place well
well. Manager cannot make this type
of suggestions.
9
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Improvement at parts picking

work at warehouse

10

KAIZEN practice starts with small

improvement

1. The picture shows a picking cart.

2. More than one picking carts are working in the
parts storage area for picking up the parts.
3. The width of cart lane is minimized to increase
the storage capacity
4. It has disturbed the carts form moving smoothly
5 A worker suggested to draw a centerline on the
5.
picking lane to avoid collision
Research Institute Corp.

Example (2)
Prevent picking carts from collision by
securing the moving space with
centerline on the picking lane
=>
>P
Productivity
d ti it iimprovementt

Example (3)
Save searching time of tools by storing
them in order
=> Productivity improvement

11

12

KAIZEN practice starts with small

improvement

Improvement in tool search time

1. It takes time to find out necessary tools to be
used from disorganized tool boxes. Further, it
sometimes causes tools missing.
2. Tools can be found easily, if the tool labels are
put on the tool box or tool board
3. This suggestion reduced the waste time
4 This is a part of 5S(Five-S) activities
4.

Research Institute Corp.

Example (4)
Save searching time of materials by
storing them in order
=> Productivity improvement

13

Improvement for material search

time to shorten at warehouse

Recognition

1. Unnecessary materials may increase if it is not

controlled well
well,
2. It will take time to find out necessary materials, if
it is stored with the unnecessary materials
materials.
3. If the unnecessary materials are removed,
searching time of the necessary materials can
be reduced.
4 Putting material labels on the shelf will also
4.
improve the searching works.
5 This is a part of 5S(Five
5.
5S(Five-S)
S) activities.
activities
Research Institute Corp.

14

15

Recognition of the efforts of the employees will

significantly increase the motivation for the
KAIZEN participants.
Following is an example of recognition of their
efforts by posting the record of their efforts on a
board
boa
da
at the
e workplace.
o p ace

Research Institute Corp.

16

KAIZEN is a bottom up
p activities
involving employees,
who know the workplace operation best
Suggestion system
makes employees
easy to submit ideas
or plans
plans,
which may improve
daily works

Top Down
Management
Section Manager

Proposal

Staff
Manpower Structure of Company

Bottom Up
17

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Concept of Suggestion Activity

18

A sample of
suggestion
gg
sheet

1. Involve all the members into KAIZEN activities

2 Number of submitted suggestions is more important
2.
important,
rather than the impacts and effects of the suggestions.
3. On the average, one suggestion may be effective
out of 10 suggestions submitted.
4. Awards for the useful suggestions will promote further
suggestions.
5. Suggestion Committee should be organized to
evaluate the suggestions
suggestions.

Research Institute Corp.

Research Institute Corp.

19

Suggestion
The suggestion
sheet will be
returned to the
proposer
p
p
with comment/
responses
p
from
the evaluation
committee

Comments/
responses from
the committee

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20

Advantage of Small Group Discussions

The number of suggestions increases year by year

1.
No. of items pe
er one pe
erson

2.
3.

Easy to discuss on the topics common among the

group members
All the members can join the discussion without feeling
self-consciousness
Member can understand their roles

Organize a small group

p
2. Within the same workplace
3. Number of members should be 5-7 maximum
4. Group has its own group name
1.

By Toshiba Engineering Co., LTD.

21

Research Institute Corp.

22

Research Institute Corp.

Sustained Activities

Effects of KAIZEN approach

B Small
By
S ll G
Gorup activity
ti it
Organize small group

Objective of the company

Needs of individual

to get profit,
profit etc

Self Actualization

select a leader
Next Theme
All
groups

Realization through small group activities

Improvement of work environment, which enables
the realization of capability of individual employees
Productivity improvement

I
Improvement
t off company performance
f
Research

Institute Corp.

23

Grasp current
state

presentation

Set theme

Evaluation, lessons learned

Set target

prevent occur again

schedule role
schedule,

Confirm effect

reason, select theme

countermeasures
and execute

cause and effect

diagram
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24

- END Reference
1. U
1
Ueda
d Toshio,New
T hi N
D
Development
l
t off Small
S ll group A
Activities,
ti iti
S
Sannou
U i 1991
Univ.
1991
2. Nikkeiren KouhoubuPresentation Skill at Workshop meeting and Small group
Activities1992
3 Kajihara YutakaExecution
3.
Y taka E ec tion of Small gro
group
p Acti
ActivitiesManagement
ities Management P
Publish
blish
1982
4. Toshiba Engineering Co.Increasement of Intelligent ProductitityKanki
Publish 1987
Publish1987
5. Sannou Univ., Quality Management
6. Niigata Engineering Co. Small group Activities1995

Ver3.2)101220

Research Institute Corp.

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