Kaizen Examples

1. All the employees are involved in taking Kaizen Shapath

2. Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Em ployees

3. Director to Doorman - all are equally involved in doing Kaizen at GEMBA

4. Preventive Maintenance through Visual Management

5. Visual Management – Pigments stored in all the containers are visible and known Transparent containers

6. Through color coding, it is easy to know which tools and components belong to which dept.

7. PEEP (Place For Everything and Everything in its Place) When the person has taken a tool , he will place a token at the place that will let others know where the tool is now and with whom Token

8. Standard WIP Output Input Frontline workers are cleaning their workstations to keep their workplace dust-free Standard WIP has been kept near every workstation All the components have been color coded according to their functionality and stored at the point of use (POU) Color coding

9. This is an example of One Piece Flow Assembly Each and every component needed is available at a hands distance of the worker Plan vs. Actual production display board Light indicator to give signal Packaging Material at hands distance

10. Learning C enter - where all kinds of tools are kept to train the employees Worn out/Waste tools are kept in one line

11. SMED trolley All the tools required (related to the machine) to perform the changeover are available in SMED trolley. Big stand is available in the left corner where all the tools are kept that will be needed during changeover, it helps to avoid Muda of Motion & Transportation

12. SMED trolley contains all the tools required to perform quick changeover. SMED trolley has been parked only in the right area Responsibility has been assigned to Shift Fitter

13. Place for everything and every useful thing in its place (PEEP) Kanban system No stock out or over-stocking of material

14. Kanban Collection tray Once any material has been picked up for use, the Kanban card of the particular material will go into the Kanban collection tray. It will then be sent to purchase department at every 11 am & 4 pm daily for placing the replenishment orders

15. Whenever the operators need some material, they trigger the light that gives signal to Mizusumashi (Water Spider) who replenishes the required material in the workstation Mizusumashi (Water Spider) Light signal

16. Point of Use Storage (POUS ) with Kanban Responsibility assigned Kanban Card Kanban Board

17. Visual Management Count Free No Oil Drops on the Floor Name of the Oil stored Same color marking is done on M/C

18. Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer

19. Kaizen For kids (KFK)

20. Yogesh Vaghani discussing the importance of Kaizen with S chool Faculty