© Total Quality Management, JSW Group

Series C

TQM Training Module on

Kaizen, OPL, Poka Yoke
Doc. No. C-21.02.20180601
Revision 02; 01st June 2018
Authors: Pankaj Lochan

For further clarifications, write to pankaj.lochan@jsw.in © Total Quality Management , JSW Group
 © Total Quality Management, JSW Group

TQM Training Series: 6 series with 66 training modules

This is a training module on Kaizen, OPL and Poka Yoke (C-21)

Series-A Series-C Series-D Series-F

Basic Problem Solving Tools Quality Management Basics Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Value Stream Mapping (VSM) F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Time & Motion Study F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 SMED F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Wrench Time Analysis F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 Queuing Theory F-05 Factorial DoE
A-06 Check Sheets C-06 Strategic Analysis Tools D-06 Inventory Management F-06 Principal Component Analysis
A-07 Histogram C-07 Policy Management D-07 Linear Programming Problem F-07 Cluster Analysis
C-08 Policy Diagnosis F-08 Conjoint Analysis
A-08 Pareto Charts D-08 Game Theory
C-09 Daily Management F-09 Discriminant Analysis
A-09 Graphs D-09 OEE
C-10 Daily Mgmt. in Maintenance F-10 Factor Analysis
D-10 PERT & CPM
Series-B C-11 Cross Functional Mgmt. F-11 Response Surface Method
C-12 Quality Assurance Basics
Basic Management Tools F-12 Taguchi DoE
C-13 MSA
B-01 Brainstorming Series-E F-13 Weibull Analysis
C-14 PFD, FMEA, Control Plan
B-02 Affinity Diagram Decision-making Tools
C-15 Cost of Poor Quality (COPQ)
B-03 Arrow Diagram C-16 Improvement Fundamentals E-01 Quality Function Deployment
B-04 Tree Diagram C-17 4i Methodology E-02 Fault Tree Analysis
B-05 PDPC C-18 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram C-19 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis C-20 QC Story Approach E-05 Time Motion Series
B-08 Relation Diagram C-21 Kaizen, OPL, Poka Yoke
 © Total Quality Management, JSW Group

Clarification of common terms

Terms Full form Explanation

Literally means “small change” in Japanese; used parallel to the English word improvement”. Commonly used
Kaizen Kaizen
today for small improvements and is a continuous improvement tool in the TQM philosophy
Kaizen An improvement presentation format which shows an improvement (Kaizen) in a BEFORE-AFTER format
format
A3 Another 7-step improvement presentation format (developed at Toyota) based on PDCA. Has the steps –
format Background, Current situation, Goal, Root Cause, Countermeasures, Effect (or impact), Follow up actions
A 7/8 step problem solving methodology based on PDCA which the QC members use basic tools to solve
QC Story QC Story
problems in a Quality Circles
Small Group A generic term used for employee engagement activities in an organisation where people work in small
SGA
Activities groups to solve problems of their work area. This is generally used for employee motivation & morale
Quality Control
QCC Same as Quality Circles; were known earlier (in Japan) as QCC
Circles
A group of voluntary workers who agree to work on problems in their area and create this forum to solve their
QC Quality Circle
problems
Plan-Do-Check- An iterative 4 step Problem Solving methodology which assumes that problem is solved best when you follow
PDCA
Act this cycle P-D-C-A
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 Strong applicability
Employee Engagement Activities: Forums and output formats  Weak applicability

Improvement
Kaizen format QC Story
/ output PDCA format A3 format VJNR’s 4i
Improve- (Before & format
format (4-step) (7-step) Methodology
ment Forums After) (7-step)

Quality Circles     
Problem Specific /
thematic Group
brainstorming     
(Manthan)

Individual small
Improvements (Kaizens)     
Innovations     
 © Total Quality Management, JSW Group

What is KAIZEN

Continual Improvement
Process
Continual Improvement
Improvement Project  Data Driven Methodology to Magnify Project
Implemented
Impact of Process Improvement
Savings

Savings
 Apply Control Techniques to Eliminate
Erosion of Improvements
Maintenance
of Process  Proceduralize/Standardize Improvements
Performance
for Improved Maint. of Critical Process
Parameters Time
Time
Continual Improvement Projects Emphasize Control and Long Term Maintenance

KAI + ZEN
Kaizen
Kaizen

Savings
To modify, Think, make  Use Small Teams to Optimize Process CPI
to change good, make Performance by Implementing
better Incremental Change
Kaizen Projects Emphasize  Apply Intellectual Capital of Team
Incremental Improvements Members Intimate with Process
Time
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KAIZEN format
• Kaizen emphasizes on
small improvements
• Most elementary KAIZEN
format is shown
• It uses a “BEFORE-AFTER”
format to represent
improvement along with
basic analysis or root cause
analysis, whatever may be
required.
• Specific forms of KAIZEN
may include POKA YOKE
(Error proofing) etc
© Total Quality Management, JSW Group
KAIZEN
Example - 1

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 KAIZEN
Kaizen For Diffuser Chamber Example - 2

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 KAIZEN
Kaizen For Modification Of Pipeline Re-routing Example - 3

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 KAIZEN
Kaizen For Reducing Cycle Unloading Time Example - 4

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 KAIZEN
Example - 4
 KAIZEN
Example - 5
 KAIZEN
Example - 5
PDCA - 1

INCREASING CENTRAL WORKING INDEX OF BLAST FURNACE #4 11-Jun-18 15

11-Jun-18 68
 KAIZEN
Example - 6
PDCA - 1

INCREASING CENTRAL WORKING INDEX OF BLAST FURNACE #4 11-Jun-18 15


POKA-YOKE
What is POKA YOKE?
 Poka Yoke, Mistake Proofing or Error
Proofing emerged out of Lean’s quest for
ZDQ (Zero Defect Quality)
 Mistake-proofing systems
 Most Poka-yoke devices are sensor or jig
devices that assure 100% compliance all the
time!
 Does not rely on operators catching
mistakes; it identifies the defect
immediately at point of Origin Inspection
and,
 Provides feedback for corrective action, a
quick feedback 100% of the time
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Approaches in POKA Yoke
Two Poka-Yoke System
approaches are utilized in
manufacturing which lead to
successful ZDQ:
1. Control Approach – shuts
down the process when an
error occurs. Or keeps the
“suspect” part in place when
an operation is incomplete.
2. Warning Approach - Signals
the operator to stop the
process and correct the
problem.
© Total Quality Management, JSW Group
Methods in Poka Yoke
Poka-yoke systems consist of
three primary methods:
1. Contact
2. Counting
3. Motion-Sequence
Each method can be used in a
control system or a warning
system.
Each method uses a different
process prevention approach for
dealing with irregularities.
 © Total Quality Management,
POKAJSW Group
YOKE
Plant Example - 1

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© Total Quality Management,
POKAJSW Group
YOKE
Plant Example - 2
© Total Quality Management,
POKAJSW Group
YOKE
Plant Example - 3
 © Total Quality Management, JSW Group

ONE POINT LESSON (OPL)

 One Point Lesson (OPL) or Single

Point Lessons help you quickly
communicate key points on a
subject
 It may be communicated either
verbally or visually,
 It is done in one sheet,
 And must take about 5-10 minutes
to communicate and understand
 It may be used to communicate
aspects of:
 A job or task
 Equipment
 Process
 Safety
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Types of OPLs
© Total Quality Management, JSW Group
 
ONE POINT LESSON
Generic Examples

 
  ONE POINT LESSON
Generic Examples

 
 DEPARTMENT:
ONE POINT LESSON ONEAREA: DATE:
POINT LESSON
HSM#2 FURNACE 02/09/2016
Plant Example - 1
TITLE: DIRECTION OF MOUNTING FOR SOLENOID VALVE 6014 ON GAS & AIR SHUT-OFF VALVES
Basic
CLASSIFICATION: Improvement Trouble Case
Knowledge
Equipment
OBJECTIVE: Quality Safety Maintenance Operation

PROBLEM CASE IMPROVEMENT LESSON

AIR IN AIR OUT

AIR OUT
AIR IN

Inference: Check the marking on the valve. P – stands for Pressure or air inlet and
A – Stands for actuator or air outlet Details Name Signature
Prepared By: A. Manoj Kumar
Head:
Section:
ONE POINT LESSON
Plant Example - 2
 ONE POINT LESSON
Plant Example - 3

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 ONE POINT LESSON
Plant Example- 4

Wrong Correct

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