Kaizen training

1. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 1
TRAINING ON TRAINING ON
KAIZENKAIZEN
SUKIN.S.SHETTYSUKIN.S.SHETTY

2. KAIZEN TRAINING 2TOKAI RIKA MINDA INDIA PVT LTD
TOPICS TO BE DISCUSSEDTOPICS TO BE DISCUSSED
INTRODUCTION OF KAIZENINTRODUCTION OF KAIZEN
7 TYPES OF WASTES7 TYPES OF WASTES
WHY KAIZENWHY KAIZEN
8 KEY ELEMENTS OF KAIZEN CULTURE8 KEY ELEMENTS OF KAIZEN CULTURE
KAIZEN MINDSETKAIZEN MINDSET
TOYOTA PRODUCTION SYSTEMTOYOTA PRODUCTION SYSTEM
BENEFITS OF KAIZENBENEFITS OF KAIZEN
HOW TO IMPLEMENT KAIZENHOW TO IMPLEMENT KAIZEN

3. KAIZEN TRAINING 3TOKAI RIKA MINDA INDIA PVT LTD
INTRODUCTIONINTRODUCTION
KAIZEN MEANS CONTINUOUS IMPROVEMENT
IN JAPAN :
KAIZEN CHANGE FOR BEKAIZEN CHANGE FOR BETTERTTER

4. KAIZEN TRAINING 4TOKAI RIKA MINDA INDIA PVT LTD

5. KAIZEN TRAINING 5TOKAI RIKA MINDA INDIA PVT LTD
TPS created KAIZEN based on DEMINGS cycle or PDSA cycle

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MAKE EVRYTHING AS SIMPLE AS MAKE EVRYTHING AS SIMPLE AS
POSSIBLE BUT NOT SIMPLERPOSSIBLE BUT NOT SIMPLER
----ALBERT EINSTIENALBERT EINSTIEN

7. KAIZEN TRAINING 7TOKAI RIKA MINDA INDIA PVT LTD
KAIZEN is a system of continuous improvement in KAIZEN is a system of continuous improvement in
quality, technology, process, company culture, quality, technology, process, company culture,
productivity, safety and leadership.productivity, safety and leadership.
KAIZEN was developed in 1950 after the world warKAIZEN was developed in 1950 after the world war--II II
by by TAIICHI OHNOTAIICHI OHNOand and SHIGEO SHINGOSHIGEO SHINGObased on based on
DEMINGS CYCLEDEMINGS CYCLE or or SHEWART CYCLESHEWART CYCLE or or PSDA PSDA
CYCLECYCLE..
KAIZEN involves setting standards and then KAIZEN involves setting standards and then
continuously improving those standardscontinuously improving those standards

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DEMINGS CYCLEDEMINGS CYCLE

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DEMINGS CYCLEDEMINGS CYCLE
DEMINGS CYCLE or SHEWART CYCLE or PSDA DEMINGS CYCLE or SHEWART CYCLE or PSDA
CYCLE found by EDWARDS DEMINGS AND WALTER CYCLE found by EDWARDS DEMINGS AND WALTER
SHEWARTSHEWART
It is a continuous quantity improvement model It is a continuous quantity improvement model
consisting of a logical sequence of four repetition consisting of a logical sequence of four repetition
steps for continuous improvement and learningsteps for continuous improvement and learning
PLAN PLAN AHEAD FOR CHANGE. ANALYSE & PLAN PLAN AHEAD FOR CHANGE. ANALYSE & PREDICTPREDICT
RESULTSRESULTS
DO EXCUTE THE PLAN TAKING SMALL STDO EXCUTE THE PLAN TAKING SMALL STEPS.EPS.
STUDY CHECK AND STUDY THE RESULTSSTUDY CHECK AND STUDY THE RESULTS
ACT TAKE ACTION TO STANDARDIZEACT TAKE ACTION TO STANDARDIZE

11. KAIZEN TRAINING 11TOKAI RIKA MINDA INDIA PVT LTD
KAIZEN CYCLEKAIZEN CYCLE
START START
HEREHERE
IDENTIFY WASTE
PLAN COUNTER
MEASURES
REALITY CHECKREALITY CHECK
MAKE CHANGESMAKE CHANGES
VERIFYVERIFY
MAKE MAKE
STANDARDSTANDARD
CELEBRATECELEBRATE

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7 types of wastes 7 types of wastes

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7 types of wastes 7 types of wastes wastewaste MUDAMUDA
1.1.Over production Over production ----Production more than required.Production more than required.
2.2.WAITING WAITING ––Process delays idle time.Process delays idle time.
3.3.TRANSPORTATION TRANSPORTATION ––Delay in material handling.Delay in material handling.
4.4.EXCESS INVENTORY EXCESS INVENTORY ––Excess of raw material & tools for Excess of raw material & tools for
production.production.
5.5.Motion Motion ––Actions of people or equipment that do not add value.Actions of people or equipment that do not add value.
6.6.OVER PROCESSING OVER PROCESSING ––Unnecessary stops or work elements or Unnecessary stops or work elements or
procedures.procedures.
7.7.DEFECTIVE UNITS DEFECTIVE UNITS ––Production of a part that is scrapped or Production of a part that is scrapped or
require work. require work.

15. KAIZEN TRAINING 15TOKAI RIKA MINDA INDIA PVT LTD
The foundation of Kaizen method consists of 5 The foundation of Kaizen method consists of 5
founding methods :founding methods :
1.1.Team workTeam work
2.2.Personal disciplinePersonal discipline
3.3.Improved MoraleImproved Morale
4.4.Quality circlesQuality circles
5.5.Suggestions for improvement.Suggestions for improvement.

16. KAIZEN TRAINING 16TOKAI RIKA MINDA INDIA PVT LTD
Improved Morale : Improved Morale :
Quality circles : Employee participation program.Quality circles : Employee participation program.
It consists of employees who meet It consists of employees who meet
periodically to identify strength and weakness in periodically to identify strength and weakness in
productionproduction

17. KAIZEN TRAINING 17TOKAI RIKA MINDA INDIA PVT LTD
WHY KAIZENWHY KAIZEN
1.1.To eliminate waste in organization.To eliminate waste in organization.
2.2.To increase productivity.To increase productivity.
3.3.To improve qualityTo improve quality
4.4.Customer satisfaction.Customer satisfaction.
5.5.Growth of the organization.Growth of the organization.
6.6.To eliminate any abnormalities & stopping of limitsTo eliminate any abnormalities & stopping of limits
7. Developing self personality.7. Developing self personality.

18. KAIZEN TRAINING 18TOKAI RIKA MINDA INDIA PVT LTD
8 KEY ELEMENTS OF KAIZEN CULTURE8 KEY ELEMENTS OF KAIZEN CULTURE
1.1.KAIZEN MINDSETKAIZEN MINDSET
2.2.CUSTOMER ORIENTATIONCUSTOMER ORIENTATION
3.3.QUALITY CONTROL CIRCLESQUALITY CONTROL CIRCLES
4.4.SUGGESTION SYSTEMSUGGESTION SYSTEM
5.5.DISCIPLINE IN WORKPLACEDISCIPLINE IN WORKPLACE
6.6.SMALL GROUP ACTIVITIESSMALL GROUP ACTIVITIES
7.7.COCO--OPERATIVE RELATIONSOPERATIVE RELATIONS
8.8.TOTAL QUALITY MANGEMENT.TOTAL QUALITY MANGEMENT.

19. KAIZEN TRAINING 19TOKAI RIKA MINDA INDIA PVT LTD
KAIZENMINDSETKAIZENMINDSET
1.EVERYTHING CAN & SHOULD BE IMPROVED
2.NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF
IMPROVEMENT.
3.IMAGINE THE IDEAL CUSTOMER EXPERIENCE AND STRIVE TO
PROVIDE IT.
4.DON’T JUST CRITICIZE,SUGGEST AN IMPROVEMENT.
5.THINK OF HOW TO IMPROVE IT INSTEAD OF WHY IT CANT.
6.SET TARGET AND MOTIVATE YOURSELF TO ACHIVE IT.
7.USE COMPTETION TO AROUSE INTEREST.
8.DON’T LOOK FOR REWARDS.
9.GENERATE MORE QUESTIONS.
10.SAY YOURSELF I CAN DO ITI CAN DO IT

20. KAIZEN TRAINING 20TOKAI RIKA MINDA INDIA PVT LTD
TOYOTA PRODUCTION SYSTEMTOYOTA PRODUCTION SYSTEM --TPSTPS
TAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 19 75.
They visited several FORD motor company automotive plants in Michigan.
But observed some methods not very effective . Then by chance they
visited supermarket Piggly Wiggly. They were inspired how the products
were re ordered and restocked goods. Reducing inventory by usingjust in
time ( JIT) inventory system. Using easy methods to display their goods
and arranging manpower only wherever required. They were doing good
business with less investment.
Main objective of TPS was :
1.Reduce inventory by following JIT.
2.Standardised work management.
3.Continuous improvement.
4.Lean manufacturing
5.Customer satisfaction

21. KAIZEN TRAINING 21TOKAI RIKA MINDA INDIA PVT LTD
KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN AND
WEST
1.Deals with quality of
products.
2.Manufacturer oriented
3.Product oriented aimed at
detecting and eliminating
defected parts.
4.Responsibility of quality
control managers.
1.Deals with quality of
products
2.Customer oriented.
3.Process oriented aimed at
improving the total
performance.
4.Company wide, everybody
is responsible.
WESTWEST JAPANJAPAN

22. KAIZEN TRAINING 22TOKAI RIKA MINDA INDIA PVT LTD
BENEFITS OF KAIZENBENEFITS OF KAIZEN
1.Savings in energy, material & others resources.
2.Improvements in working environment.
3.Improvements in machines & process.
4.Improvements in jigs & tools.
5.Capable of generating new ideas.
6.Customer satisfaction.
7.Elimination of wastes.
8.Improvement in product quality.
9.Improvement in 5S.
10.Improvement in self personality.
11.Improvements in own work..

23. KAIZEN TRAINING 23TOKAI RIKA MINDA INDIA PVT LTD
HOW TO IMPLEMENT KAIZENHOW TO IMPLEMENT KAIZEN
Employee identifies problem, waste or Employee identifies problem, waste or
an opportunity for improvement and an opportunity for improvement and
write it downwrite it down
The employee develops an improvement The employee develops an improvement
idea & discuss with his or her idea & discuss with his or her
supervisorsupervisor

24. KAIZEN TRAINING 24TOKAI RIKA MINDA INDIA PVT LTD
The supervisor reviews the idea within The supervisor reviews the idea within
24hrs & encourages immediate action.24hrs & encourages immediate action.
The employee implements the ideaThe employee implements the idea
The idea is written upon a simple Kaizen The idea is written upon a simple Kaizen
sheetsheet

25. KAIZEN TRAINING 25TOKAI RIKA MINDA INDIA PVT LTD
Supervisor publishes the Kaizen and rewards Supervisor publishes the Kaizen and rewards
will be givenwill be given
CELEBRATE THE SUCCESS OF YOUR KAIZENCELEBRATE THE SUCCESS OF YOUR KAIZEN

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