1.Kaizen overview(VTCS DODOMA).pptxnnnnn

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1. Overview of KAIZEN VHTTI ARUSHA MARCH , 2025 1 VOCATIONAL EDUCATION AND TRAINING AUTHORITY （ DATS-Teachers Training workshop

2. 2 Contents 1. Basic Concept of KAIZEN 2. Why are KAIZEN Activities necessary? 3. KAIZEN in action 　 4. Example of KAIZEN 5. Summary

3. Basic Concept of KAIZEN 3

4. 1. Situations in our VTC,DVTC & RVTSC 4

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25. 　 “Kaizen” is an activity to improve 　 productivity by utilizing existing resources . What is Kaizen? 25 In Japanese Kaizen means 　　 “ improvement ” or “ change for the better ”. 　 By improving standardized activities and 　 processes, kaizen aims to eliminate 　 waste( Muda ). ★

26. Kaizen features Small steps but continuous 26 KAIZEN : Accumulation of small step and continuous improvement Turtle Rabbit

27. Kaizen Safety Improvement Improve product process Making Work Easy Improve Quality Increase Sales Increase Productivity Employees 　 satisfaction Cost reduction Objectives of KAIZEN (Example) 27 ★

28. 28 KAIZEN and Innovation KAIZEN (Accumulation of small step and continuous improvement) Innovation (Capital investment, Introduction of new engineering technology)

29. 29 Comparison of KAIZEN and Innovation KAIZEN Innovation Subject Problems pointed out from present process and operation Strategic issues for company’s future development Effect Gradual progress Drastic progress Features People-oriented Accumulation of small steps Technology-oriented Land marking break through Investment Little Large Person in charge All employees Top management and staff Technology 5S, IE, QC, etc. Specific engineering technology

30. 2.Why are KAIZEN Activities necessary? 30

31. Customers want to buy high quality products cheaply Investors want to receive much dividends 　 The company must produce high quality products efficiently. Satisfactory Customer Investor Company Why are KAIZEN Activities Necessary? 31

32. 32 Why are KAIZEN Activities Necessary? Objectives of the company Seeking Profits Profits Continuation of the company To Improve Stakeholders (Government, workers ,trainees ,companies, etc) satisfaction Elimination of “Muda” Cost Reduction Quality Improvement Delivery Time Training for the workers

33. 1. Purpose Cost reduction by complete elimination of “ Muda ” (Waste / Non-Value Added) Full participation (From the president to the field workers) Eliminate anything wasteful, uneven, or over-burdening. Improvement Quality Decrease Defects Reduce Muda Increase Productivity Reduce Cost 33 Why are KAIZEN Activities Necessary?

34. 34 Customers tend to select suppliers which offer products or services at competitive prices. Therefore, enterprises must build up the system which can provide value-added products or services at competitive prices. Kaizen Decided in a market Price Cost Profit Profit = Price - Cost ２ .Concept of Costs Controlled by idea and actions Why are KAIZEN Activities Necessary?

35. Focal points to check to find out existing problems 35 How to Find the Problems in Operations Six major production elements Quality, Cost, Production Volume, Delivery, Safety, and Motivation Four “M”s M an, M achine, M aterial, M ethod Three “M”s Muda Mura Muri ( Waste ) ( Unevenness ) ( Overburden )

36. a. Quality Quality improvement, No complaint , Fewer irregularities, Prevention of errors, Improvement in reliabilities b. Cost Better cost control , Reduction of processing, Time management , Reduction of raw materials c. Production Volume Increase in the productivity, Prevention of the accidents , Fewer raw materials d. Delivery Work period, Simple procedure, Decrease in inventory e. Safety Decrease in negligent error , 　 Comfortable environment, Workshop cleaning, f. Motivation Attitude toward KAIZEN activities, Decrease absence ratio, Clean environment, Good relationship (1) Check the following six major production elements. 36 How to Find the Problems in Operations

37. 37 Material Machine Method Man How to Find the Problems in Operations (2) Check the following 4 “M”s.

38. (2) Check the following 4 “M”s. 38 How to Find the Problems in Operations a. Man Experience and knowledge, Skills, Health condition, Job training, Attitude, Mind-setting b. Machine Machine performance, Processing productivity, Damages, Maintenance, Abnormal operation. c. Material Raw material , Final material, Quality, Quantity, Supplier, Treatment, d. Method Operation Standard, Procedure, Irregularities, Room temperature, Humidity, Lights, Air-condition, Transportation

39. （３） Finding existing problems by checking 3 “M”s 39 How to Find the Problems in Operations a.Muda : Production factors that increase cost. All no-value-added operation b. Mura: Variation in work distribution, production capacity of machinery, and material specifications c. Muri : Mental and physical overburden on operators, and overburden on production machinery (Waste) (Unevenness) (Overburden)

40. How to find out n o value added operation or Muda (waste) Standards are required to prevent from making n o value added operation or Muda. 　 Standardization of working environment １ Standard Operation ２ To increase efficiency ⇒ Eliminate Muda ３ 　 Kaizen Starter 　 Standardization of working environment ⇒５Ｓ 40

41. 41 What is 5S ? Japanese English Your language Meaning Example Seiri Sort SASAMBUA Throw away unnecessary items & Keep 　 only necessary items Organization/ fixed quantity Seiton Set in order SETI Fixing Location 　 Material & Amount 30 second retrieval of documents, tools Seiso Shine SAFISHA Cleaning/ Inspection Individual cleaning responsibility Seiketsu Standardize SANIFISHA Standardization or Hygiene Transparency of storage Shitsuke Sustain SHIKILIA Self Discipline Do 5S daily/ Awarding ★

42. 　 Effects of ５Ｓ 5S is basics of all kaizen activities . ５ S makes everyone easily recognize conditions to be normal or abnormal . Eliminating Muda in the workplaces through 5S , brings the improvement 　 of operation , working efficiency and the safety environment . 42

43. １． Improvement the efficiency of work ２． Improvement quality of work 3 ． Appeal ・ To 　 reduce material searching time. ・ To decrease transportation time . ・ To reduce facilities trouble by dirt or rubbish. ・ To utilize space efficient. ・ To reduce mistakes in choices of raw 　 materials and products. ・ Beautiful and well ordered facilities give good impressions to visitors. 43 　 Effects of ５Ｓ

44. 44 3-2.Standard Operation & Elimination Muda

45. 45 Consist of Operation Eliminate “ Muda ” as much as possible Operation Net Operation No value added operation Muda (Waste) Muda 　 ( overproduction, 　　　　 inventory , 　　　　 transporting, 　　　　 Defect-Making ) Operation No value added operation （ Picking up material Inspection, removing dust ） Net operation ★

46. 46 “ Seven Muda ” 1) “ Muda ” of Overproductio ｎ 2) “ Muda ” of Inventory 3) “ Muda ” of Waiting 4) “ Muda ” in Transporting 5) “ Muda ” of Defect-making 6) “ Muda ” of Motion 7) “ Muda ” in Processing Seven types of “ Muda ” Muda gives extra cost to products with no added value.

47. 　 1. Standard Operation An efficient production method which eliminates Muda of procedures. 2. Objectives of Standard Operation 1) To clarify the rules for the production method a. A basic factor for the production method and control. b. To decide the procedure with due consideration for quality, volume, cost and safety. 2) Good tools for improvement a. No standard (no distinction between normal and abnormal), no improvement. b. To find out what is wasteful, uneven, and overburdening. 　 47 Standard Operation

48. 48 Standard operation is an operation’s detailed performing procedures. Standard operation can be performed by anyone assigned for the task and is regarded as the best at the moment. In the KAIZEN standpoint, standard operation serves 　 as a good starting point for any improvement. Standard Operation

49. 4.Example of KAIZEN 49

50. 50 Ex. Reduction of seeking time Before The perforated metal sheets are placed on the shelf randomly and it was not easy to pick up necessary ones. After The sheets are classified and hanged on a tree-liked stand . It became easy to find and pick up necessary ones.

51. 51 Ex. Easy transportation Before The pressed pieces were put in the container which is not equipped with wheels. After A pressed pieces are put in the wheeled container so that they can be conveyed easily.

52. 52 Ex. Reduction of fatigue Before The parts container was placed on the floor . A worker had to bend over each time to pick up parts, which damaged his back . After The container is put on a stand. A worker does not have to bend over to pick up parts. He does not suffer an injury to his back.

53. 53 5S, inventory control and layout changes were implemented. As the result, 788 ㎡ of free space was created , and this area was rented to another company. Ex. Creating Free Space

54. 5.Summary 54

55. Benefits of KAIZEN 55 Quality and prod. awareness Team spirit Interpersonal relations Self confidence, etc. Improvement of Quality , Productivity and Working environment Tangible benefits Intangible benefits ＋ Mindset changes

56. 56 Critical success factor for KAIZEN Enthusiasm of the top mgt. ・ Commitment ・ Support for the activity Mindset of the people in the workplace for quality and productivity ＋

57. 57 Asanteni Sana Imeandaliwa na; Fihili Challange Kaizen Consultants Reg. Na KZ-00070. VETA HQ DODOMA