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Kaizen Workshop

Conducted by: Shiraz S. Syed

What changes


Attitude is;
degree of likeness or dislikes,
positive or negative feelings
towards, people, place, event etc

Kaizen Workshop


Feeder Storage & Retrieval System

Team Leader: Shiraz S. Syed

Date & Time: October 2, 2009 at 3:30PM to 5:00PM (1st meeting)

October 9, 2009 at 3:30PM to 5:30PM (2nd meeting)

Venue: Shield Factory Conference Room

1- Definition & general information on Kaizen
2- Overview and purpose of the work shop
2- Overview of the existing feeder process
3- Facts and figures on feeder line balancing
4- Team formation
5- Team work on feeder retrieval and storage proposals
6- Teams to work on proposal presentation
7- Present proposal to DOT for approval

What is KAIZEN?

Kaizen History:

In 1950 Toyota implemented Quality Circles leading to the development of

Toyota’s unique “Toyota Production System”. Toyota System is a system
of continuous improvement in quality, technology, processes, company culture,
productivity, safety and leadership.

These continual small improvements (Kaizen) add up to major benefits.

They result, for example, in: faster delivery, lower costs, and greater customer satisfaction.

Cycle of Kaizen Activity :
1-Standardize an operation
2-Measure the standardized operation (find cycle time & amount of in-process inventory)
3-Gauge measurements against requirements
4-Innovate to meet requirements and increase productivity
5-Standardize the new, improved operations
6-Continue cycle ad infinitum

This is also known as the Shewhart cycle, Deming cycle, or PDCA.

Kaizen Tools
The following are descriptions of Kaizen tools used different organizations;

1- Value Stream Mapping (Material & Information Flow Mapping)

2- 5S (Sort, Straighten, Sweeping , Standardizing, Sustain)
3- SMED (Single Minute Exchange of Dies, mainly in automotive industry)
4- Just in Time (Takt Time, Flow, Pull System (based on customer demand)
5- TPM (Total Productive Maintenance)
6- Kanban (Card System)
7- Standard Work
8- Visual Management (Use of signs, lights & notice boards)
9- 3P (Production Preparation Process)
10- Jidoka (Autonomation)
11- Heijunka (visual scheduling tool)

Elements of Kaizen:

1- Teamwork
2- Personal discipline
3- Improved morale
4- Quality circles
5- Suggestions for improvement

The 3 Rules (TPS):
To aid an organization in the implementation of improvement ideas,
TPS offers three rules that must always be followed when making
and implementing suggestions. These are:

1) add no people to the process,

2) add no space
3) spend no money.

These three rules are very useful in channeling everybody’s mind towards
improvement that will be both valid and relatively easy to implement.

Purpose of KAIZEN is to find…

…then remove obvious waste.

Purpose of this workshop:

Purpose of the work shop is to evaluate options to

develop feeder storage and retrieval system.
Currently feeders are stacked in hap hazard way
causing line balancing issues & deterring product

Overview of the existing process

Currently feeder is being produced on Golfang

then it is transferred to Printing, after that it is
transferred into packing.

Feeders are kept in styrophome and card board

cartons. This process causes feeders to get
scratches and it attracts dust as well. Each
cartons is different size, causing difficulty for

Facts & Figures on Feeder Line Balancing

Golfang Capacity: 20,000 pcs / day

Printing Capacity: 40,000 pcs / day

Packing: 15,000 to 20,000 pcs / day, as per plan

Team Formation

Two teams will be formed. Both team will evaluate options to

develop feeder retrieval system. Each team will have one
week to make proposed presentation for feeder retrieval
system. Presentation should have following details;

1- Proposed Process (storage and retrieval)

2- Design of proposed process (w/ dimensions - Layout)
3- Number of feeder can be kept in WIP
4- Lead Time
5- Estimated Cost

Team 1 Team 2

1- Akhtar Rafee Shakeel Ahmed

2- Ahmed Abbass Afzal Muben
3- Jawaid Khan Adnan Khaliq
4- Farhan Shafiq Qaisar Subhan
5- Muhammad Maroof Faysal Qureshi
6- Usman Shams Waqas Malik
7- Sharayar Ahmed Umer Wahab

We will meet again on October 09 for presentations,

Good Luck