Kaizen in manufacturing industry

Kaizen ppt

1. Kaizen In Manufacturing Industry

2. Outline What is kaizen? Nature of kaizen 5s framework of kaizen The cycle of kaizen activity Case study on Elin Company Swot analysis Conclusion Recommendations

3. What is kaizen? From the Japanese words “kai” which means “change” and “Zen” which means “good.”  Kaizen (Continuous Improvement) is a strategy where employees at all levels of a company work together proactively to achieve regular, incremental improvements to the manufacturing process. In a sense, it combines the collective talents within a company to create a powerful engine for improvement.

4. Dual Nature Of Kaizen Kaizen is part action plan and part philosophy. Consistent application of Kaizen as an action plan develops Kaizen as a philosophy

5. 5S is the foundation of all improvements  and is  the key component of establishing a Visual Workplace. Both are a part of Kaizen a system of continual improvement which is a component of lean manufacturing.

6. The Cycle Of kaizen Activity Plan- ahead for change. Analyze the and predict the results Do- execute the plan taking small steps in controlled circumstances Check- study the results means comparing actual results against the expected results Action - Take action to standardize or improve the process

7. Practical Study on Elin Company Elin has manufacturing facilities at Ghaziabad, near New Delhi, The company has been constantly delighting its customers with competitive products by focusing on continuous improvements in its systems & processes. Apart from JMG (Juicer Mixer Grinder),Dry and Stream Irons, Hair Dryers, Flash Lights and VISI cooler.

8. Case Study On Elin Company The assembly line consist of 34 operations and 39 operators working collectively to make a VISI cooler. It is observed that there is imbalance in the assembly line. Some operation consumes more time then the Takt time for each processes. Takt time calculation before Kaizen Takt time = Net available time per shift/no of pieces= 420/600=0.7 minute= 42 seconds This Takt time is calculate by considering all processes and parameters standardized. This includes no waste and no human fatigue. Here machine fault time, material delay, defected pieces and other non value added activities are not calculated

9. Implementation Of Kaizen In Elin Company (A Cooler Industry) Kaizen helped to reduce the unnecessary movements. Some operations were combined with each others Operation “Temperature Testing” involved 250 seconds which is really high and overcome by installing 4 new temperature tester. Gasket operation is another time consuming event. The operator has to fix the gasket and move the job back to nearby operator 1. The operation is clubbed and it reduced the time.

10. Implementation Of Kaizen In Elin Company (A Cooler Industry) After Kaizen implementation the result is impressive. The number of operators reduced to 33 from 39 and number of operations reduced to 30 from 34. Kaizen provided small improvements to assembly line. These small improvements on various stages adds up to big results. The time saved after Kaizen was significant. The total lead time before Kaizen was 1505 seconds while after Kaizen is 1039 seconds. A total saving of 466 seconds. It is well said that for any organization time is money. The flow of assembly line is much smoother now and there is reduction in the waiting time for operators. The ultimate achievements of Kaizen implementation was improved productivity, reduced cycle time, more number of jobs per shift and satisfied customers.

11. Swot Analysis Strengths Products manufacturing according to customer needs Financial strengths stabled Kaizen helps to increase productivity Weaknesses Employees skills need to be upgraded Faces heavy competition Difficulty to implement the kaizen in existing system

12. Swot Analysis Opportunities Adapt the latest technologies Company has complex assembly of products and able to produce many Trends in increasing consumer purchasing power Threats Higher cost of utilities Regulations of Govt & taxes Tough competition

13. Conclusion Kaizen philosophy if implemented well will produce marvellous result. In this cooler industry the Kaizen reduced the cycle time for various processes. Kaizen toolbox helped to find the cause of the extra time taken by the operators. This study is the proof that Kaizen will help organizations to outperform peers and achieve high performance with optimum use of resources. Kaizen is a continuous process and needs regular attention. It can be concluded that if implemented well Kaizen can yield

14. Recommendations The kaizen methodology requires training staff and management, so the company should trained their employees and upgraded their skills. Company should maintain a practice of open communication for kaizen to be efficient and employees should be given the opportunity to give their reviews without any fear