7/7/2019

1
THE SPIRIT
OF
KAIZEN
PRESENTED BY F R KHAN
MD, BTI
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2 CONTENT:

• Swift Introduction to Kaizen : 3 March

• Boost Morale : 10 March
• Cut Cost : 24 March
• Improve Quality : 31 March
• Develop New Product and Services
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3 CONTINUED:

• Increase Sales
• Reduce Health Care Expenses
• When Small Steps Are Too Hard:
What to Do
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4 IMPROVE QUALITY

• SPOT LITTLE MISTAKES

• Example “A Car”
-Internal Lighting
-Seat Belt
-Dash board Clock
• Example “bti Apartment”
• -???
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5 TOYOTA EXAMPLE

• WHAT DID “TOYOTA” DO?

• DEFECTS WERE SLIPING
FOR YEARS
• AFTER WORLD WAR II
TOYOTA STARTED
“ANDON CORD”(ROPE)
TO CORRECT SMALLEST
MISTAKES
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6 NASA EXAMPLE

• PAYING ATTENTION TO
SMALLER PROBLEMS CAN
SAVE MUCH HIGHER COST
• NASA “O” RING GLITCH
A GASKET PACKING TO
SEAL LEAKAGE FINALLY
COST 7 LIVES IN
“CHALLENGER SHIP”
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7 ADDRESS PROBLEM WHILE SMALL

• In view of the massive fire occurred in • bti Construction:

the Banani area. We are now very
worried to see that all the fire fighting - Safety Net, a small issue
extinguisher at our Willows apartment - Column Tie Bar, looks small
has been expired. More so the service
team are new as such it is required to • bti Customer Service:
train them accordingly to fight the fire.
-No call Back practice attitude
• Please take some action or respond as
-Agitating Customer Complain
deem fit.
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8 ALWAYS “SMALL WARNINGS”

• ALL BIG PROBLEMS GIVES

SMALL WARNING
• THEN SMALL PROBLEMS
BECOME “BIG”
• ADDRESS THEM WHILE
SMALL
• Bti EXAMPLE ??????
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9 BE TRANSPARENT, NOT PERFECT

• RACING CARS ARE

DANGEROUS
-IS CAR MALFUNCTIONING
-ARE ALL OUTSOURCE ITEMS
CHECKED
-TRACKING BY SENSORS

• bti OUTSOURCE ITEMS

-LIFT,GENERATOR,SUBSTATIONS
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10 HIGH RELIABILITY ORGANIZATIONS

• AIR CRAFT CARRIER

• NEUCLEUR POWER
PLANT
• HOSPITALS
ARE BUILDINGS ALSO ???
-FIRE, POWER ,LOADING
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11 Warning: DO NOT HIDE PROBLEM

• LOST OF A SMALL
WRENCH IN AIRCRAFT
CAN BRING DISASTER
• ERRORS TO BE REPORTED
WITH TRANSPERANCY
NOT PUNISHED, BUT RE-
TRAIND
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12 MENTAL BLINDFOLD-1
BUT WE GOT SO MANY THINGS RIGHT
• IGNORING ROUGE MISTAKES
• bti Construction make patch work
on CRACKS
• bti Design ignores Toilet Door
Opening
• bti CSD ignores Water Hammering
• Bti Finance ignores DATE of
payment
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13 MENTAL BLINDFOLD-2
DON’T MESS WITH SUCCESS
• ONLY SUCCESS LOUDING MAY
HOLD INFORMATION
• Bti Construction early handover
• bti Design Cost optimization
• bti CSD “APPRECIATION
LETTERS”
• Bti Sales Target meet, unhappy
clients
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14 MENTAL BLINDFOLD-3
NO NEWS IS GOOD NEWS
• NO NEWS MAY ALSO BE BIG
PROBLEM BEING COOKED
• bti Construction “Good you told ”
• bti Design looking for small details
• bti BD ignores Land Owner after
DOA
• bti Audit finds all as per “SOP”
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15 MENTAL BLIDFOLD-4
WE ARE TOO SMART TO MAKE MISTAKES
• IGNORE CHECKLIST,REPORT
• bti Construction “Repeat
Procedure”
• bti Design use STANDARD colors
• bti CSD “We are NOT so smart”
• NEVER THINK WE ARE ALWAYS
THE MOST SMART ONE
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16 MENTAL BLINDFOLD-5
EVERYONE IS RESPOSIBLE
• NEVER THINK LAST MAN
CHECKED IS ONLY
RESPONSIBLE
• bti Construction GM CHECKED
• bti Design “Checked” by HOD
• bti CSD ignores Water Hammering
• bti HR sent e mail but no response
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17 MENTAL BLIDFOLD-6
RUSH TO MARKET
• CAPTURE MARKET BUT SMALL
DETAILS IGNORED
• bti Construction USES RMG
• bti Design ICONIC building look
• bti CSD starts GIFT for customers
• bti Audit determines R & D cost
• TOYOTA WAY “JOJO”(slow,steady)
• DON’T LOOSE “KAIZAN
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18 LET MISTAKES CHANGE YOUR CRITERIA

FOR SUCCESS OR FAILURE
• LET US KNOW THE MISTAKES
• HELP OUT OTHERS TO RECTIFY
• EVERYONE IN ORGANISATION
IS RESPONSIBLE
• FOLLOW KAIZAN WAY
• IDEAS FROM BOTTOM OR MID
LEVEL TO AVOID MISTAKES
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19 KAIZEN PATHWAY
MISTAKE POLICY
1. DEFINE MISTAKES “MUST”
AVOID
2. SHARE MISTAKES & SOLVE
3. ASK YOUR STAFF “WHERE ARE
THE “O” RINGS”?
4. EXTRACT LESSON FROM
MISTAKE AND SHARE IN
LARGE GROUP
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20 REVIEW VIDEO CLIP

• THE QUALITY
IMPROVEMENT
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21 THANK YOU

Open for Discussion