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

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

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.

Measurable results. 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. . Establish the baseline. Top management participation is encouraged. Kaizen events will generate quick results.

PHASES IN KAIZEN .

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

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

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 . it offered the following "5S" steps ‡ ‡ ‡ Sorting Simplifying keeping only essential items eliminates extra motion. 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. especially a shared workplace (like a shop floor or an office space).

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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