KAIZEN

PRODUCTION AND OPERATION MANAGEMENT
Kaizen ($K)
a continuous improvement process
INTRODUCTION
Masaaki Imai is known as the developer of KAIZEN. KAI means change or the action to correct ZEN means good Kaizen is a daily process, the purpose of which goes beyond simple productivity improvement. It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work.
DEFINITION
Kaizen is an improvement or ongoing improvement consisting everyone from the top management to the worker level. Kaizen philosophy is drawn from the Japanese word KAI and ZEN. Kaizen management philosophy is continuous, slow, incremental but constant improvement process.
IMPORTANCE
Focus upon continuous improvement of processes in manufacturing, engineering, game development, business management, Purchasing and logistics. Applied in healthcare, psychotherapy, life-coaching, government, banking, and other industries used in the business sense and applied to the workplace, continually improve all functions, and involves all employees from the CEO to the assembly line workers. Aims to reduce waste.
3 PRINCIPLES OF KAIZEN
1) Consider the process and the results 2) The need to look at the entire process of the job at hand and to evaluate the job as to the best way to get the job done. 3) Kaizen must be approached in such a way that no one is blamed and that the best process is put into place
FEATURES OF KAIZEN
Widely applicable Highly effective and Result oriented A learning experience Team based and cross functional Personal discipline Suggestions for improvements Quality Circles Improved morale
BASIC TOOLS FOR KAIZEN

Target Process Report Standardized Worksheet Time observation Sheet Cycle time Stack Chart Standardized Work Combination Sheet Capacity sheet Kaizen proposal sheet Kaizen Newspaper
3 Ms of Kaizen are
MURI
Muri (, unreasonable) is a Japanese term for unevenness, unreasonableness or absurdity, which has become popularized in the West by its use as a key concept in the Toyota Production System.
MUDA
Muda () is a traditional Japanese term for an activity that is wasteful and doesn't add value or is unproductive, etymologically none ()+ trivia or un-useful () in practice or others. It is also a key concept in the Toyota Production System and is one of the three types of waste that it identifies. Waste reduction is an effective way to increase profitability
MURA
Mura ( or ) is traditional general Japanese term for unevenness, irregularity or inconsistency in physical matter or human spiritual condition. It is also a key concept in performance improvement systems such as the Toyota Production System. Toyota merely picked up these three words with prefix mu-, which every Japanese know, as product improvement program or campaign.
5 Ss of Kaizen
SEIRI(sorting)
Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things per requirements and keeping them in easily-accessible places. Everything else is stored or discarded.
SEITON(Setting in Order)
There should be a place for everything and everything should be in its place. The place for each item should be clearly indicated. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. Workers should not have to bend repetitively to access materials. Each tool, part, supply, or piece of equipment should be kept close.
SEISO(Systemetic Cleanup)
Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. A key point is that maintaining cleanliness should be part of the daily work not an occasional activity initiated when things get too messy.
SEIKETSU(sanitizing)
Work practices should be consistent and standardized. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's.
SHITSUKE(Discipline)
Maintain and review standards. Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways. When an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.
2 KAIZEN LEVELS
Flow Kaizen -Focus is the overall value stream - Directed by Value Stream managers -Creating manufacturing cells,5 s, etc. Process Kaizen -Focus is on individual process -Directed by the teams work and teams leaders -Set up reduction, standard work,etc.
STEPS IN KAIZEN
PHASES OF KAIZEN
BENEFITS OF KAIZEN
Kaizen Reduces Wastes Widely accepted and can be used in both manufacturing and non manufacturing environments. Kaizen Improves space utilization, product quality A learning experience, every team member tends to learn something new. Results in higher employee moral and job satisfaction and lower turnover.
PITFALLS OF KAIZEN
Resistance to Change Lack of proper procedure to implement Too much suggestions may lead to confusion and time wastage
VARIETY OF KAIZEN
Individual Vs Teamed Kaizen Day-to-Day Vs Special Events Process Level Vs Sub process Level
BASIC TIPS
Discard conventional fixed ideas Think of how to do a process, instead of why it cannot be done. Start by questioning current practices If mistakes are made then correct them on the spot. Do not spend money for kaizen,use your wisdom. Kaizen ideas are infinite.

KAIZEN

Uploaded by

Copyright:

Available Formats

KAIZEN

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KAIZEN

Uploaded by

Copyright:

Available Formats

What is Kaizen?

What are the 3 M's of Kaizen?

PRODUCTION AND OPERATION MANAGEMENT

a continuous improvement process

BASIC TOOLS FOR KAIZEN

You might also like