Kaizen

Please verify the copyrights before reusing this presentation.It was prepared for personal use.
Best regards ,
Amit.

1. KAIZEN

2. Agenda Introduction Introduction: Man Behind Kaizen Introduction: Who does Kaizen? Why ? Kaizen Methodology Gemba Kaizen 1. Housekeeping 2. Muda elimination 3. Standardization Toyota Example Summary/Benefits of Kaizen 2

3. Introduction: Man Behind KAIZEN Masaaki Imai is known as the developer of Kaizen. He is known as the “Lean Guru” and the father of Continuous Improvement According to him In simple words Kaizen means improvement. Kaizen strategy calls for never-ending efforts for improvement involving everyone in the organization – managers and workers alike. Author of books like Kaizen (1986)Key to Japans Competitive success and Gemba Kaizen (1997) 3 http://en.wikipedia.org/wiki/Masaaki_Imai

4. Introduction: Who does KAIZEN ? Why ? WHY ? Maintenance Objective of the maintenance function is to maintain current technological, managerial, and operating standards Innovation Improvement function is aimed at improving current standards. WHO ? Kaizen Ongoing improvement involves everyone Top management Managers Workers 4 http://www.kaizen.com/

5. KAIZEN Methodology Finding out the pain area Analysis of the pain area 3M‘s Considered with the 4M‘s 3M’s  MURA , MURI , MUDA muda ("non-value-adding work") muri ("overburden") mura ("unevenness") 4M’s  MAN , MACHINE , MATERIAL , METHOD 5 http://en.wikipedia.org/wiki/Kaizen

6. Types of wastes 6 http://en.wikipedia.org/wiki/Lean_manufacturing#Types_of_waste

7. Gemba KAIZEN Gemba is a Japanese word meaning 'real place,' where the real action takes place. In business, Gemba is the ‘shop floor’ or ‘production place’ where the value-adding activities to satisfy the customer are carried out. 3 Ground rules for practicing Kaizen in Gemba are: - 1. Housekeeping, 2. Muda elimination. 3. Standardization. 7 http://www.gemba.com/

8. 1. Housekeeping 8 http://www.gemba.com/ 5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized. To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following "5S" steps Sorting- keeping only essential items Simplifying - Eliminates extra motion. Sweeping - keep the workplace clean Standardizing -Standardized work practices Sustaining - Maintaining and reviewing standards

9. 2. Muda elimination 9 http://www.gemba.com/

10. 3. Standardization Standards may be defined as the best way to do the job Products or services are created as a result of a series of processes. Certain standard must be maintained at each process in order to assure quality. Standards also can prevent recurrence of the same problem 10 http://www.gemba.com/

11. Toyota Example 11 Management Philosophy Respect for People & Continuous Improvement The success of the Toyota Production System can be attributed to Eliminating wasted time and resources Building quality into workplace systems Finding low-cost but reliable alternatives to expensive new technology Perfecting business processes Building a learning culture for continuous improvement Source : The Toyota Way , Jeffrey K. Liker  

12. Benefits of kaizen Kaizen Reduces Waste like inventory waste, time waste, workers motion Kaizen Improves space utilization, product quality Results in higher employee moral and job satisfaction, and lower turn-over. Toyota is well-known as one of the leaders in using Kaizen. In 1999 at one U.S. plant, 7,000 Toyota employees submitted over 75,000 suggestions, of which 99% were implemented. 12 http://en.wikipedia.org/wiki/Kaizen

13. Questions Please ! Thank you ! Q & A time ! 13