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Kaizen

Kaizen is a Japanese philosophy that focuses on continuous improvement of processes by making small, incremental changes each day to minimize waste. The key principles of Kaizen include considering the entire process, avoiding blame, and continuously setting and achieving higher standards through team-based collaboration and cross-functional participation. Common Kaizen tools include value stream mapping, 5S, standard work, and Kaizen events where teams simplify processes over a few days. When implemented successfully with total employee involvement and proper training, Kaizen can lower costs, increase productivity and energize employees through immediate and measurable results.

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Tata Satishkumar
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842 views36 pages

Kaizen

Kaizen is a Japanese philosophy that focuses on continuous improvement of processes by making small, incremental changes each day to minimize waste. The key principles of Kaizen include considering the entire process, avoiding blame, and continuously setting and achieving higher standards through team-based collaboration and cross-functional participation. Common Kaizen tools include value stream mapping, 5S, standard work, and Kaizen events where teams simplify processes over a few days. When implemented successfully with total employee involvement and proper training, Kaizen can lower costs, increase productivity and energize employees through immediate and measurable results.

Uploaded by

Tata Satishkumar
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Kaizen

Presented by

T satish kumar N Charan K roseline

What Does Kaizen Mean? KAI ()


To modify, the action

ZEN()
Think, make

to correct , change

good, make better

= KAIZEN
Make it easier by studying it, and making the improvement through elimination of waste.

Cont..
Kaizen A Japanese term meaning gradual unending improvement by doing little things better and setting and achieving increasingly higher standards

~ Lean Lexicon, ASQ

Small improvements generated by hands-on workers rough


the application of a variety of structured, low-technology methods ~ Office Kaizen, ASQ

Introduction
Kaizen It
is small incremental changes made for improving productivity and minimizing waste has been applied in healthcare, psychotherapy , lifecoaching, government, banking, and many other
Industries

It also applies to processes, such as purchasing and logistics ,


that cross organizational boundaries into the supply chain

The Kaizen management philosophy, therefore, is


defined as making continuous improvement slow, incremental but constant.

Kaizen Events are when work groups set aside a few


day or up to a week to simplify a process or work area -eliminating waste, creating space.

Before Kaizen

Kaizen has three main principles:


Consider the process and the results

Principles

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
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: Can be used in both manufacturing and
non-manufacturing environments

Highly effective & results oriented: Kaizen events will generate

quick results, measurable results, establish the baseline, and measure the change walk away from the event learning something new

A Learning Experience: Every member of a Kaizen team will


Team based & cross functional: Team members can be from various functions of the business. Top management participation is encourage

These Steps Are Shorten Into


A.) Select an Event B.) Plan an Event C.) Implement an Event D.) Follow-up to an Event

Types of Kaizen Events


Value Stream Mapping 5S Simplify, Straighten, Scrub, Stabilize, Sustain. Standard Work One Piece Flow

What is a Value Stream Map?


What is a Value Stream? A value stream includes all of the process steps (both value added and non-value added) that are required to complete a product, service or task. What is a Value Stream Map? VSM is a method that visually shows the material and information flows that help complete the task

Mapping a Value Stream


Current State Follow a path from end to beginning, and draw a visual representation of each step, how long it takes, key resources. Future State Draw a map of how value should flow. Opportunities to eliminate waste.

5 S in KAIZEN
5 S : A method for organizing a workplace.

To take the concept of Kaizen performance to its ultimate level

of simplicity, it offered the following 5 S steps 1) Sorting :(Seiri) Keeping only essential items 2) Simplifying:(Seiton)Eliminates extra motion 3) Sweeping: (Seiso)Keep the workplace clean 4) Standardizing: (Seiketsu)Standardized work practices 5) Sustaining:(Shitsuke)Maintaining and reviewing standards

(Manufacturing Concerns)
Kaizen Reduces Waste- like inventory waste, time

BENEFITS OF KAIZEN

waste, workers motion.etc quality.etc

Kaizen Improves space utilization, product

Results in higher employee moral and job

satisfaction, and lower turn-over

8 Wastes

Kaizen implementation tools



Pareto chart Cause and effect diagram Check sheets Histogram Scatter diagram Run charts Control charts Stratification Flow diagram Surveys

5 Ws And one H of kaizen


Who

What
Where When

Why
How

4 Ms of Kaizen
Man Material Machine Method

Continuous improvement Approach


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Defining the current strategy Defining continuous improvement objective Select continuous improvement projects Assign teams Define process Define the source of validity Develop potential improvement Perform experiments

Modify potential upgrades as required


Implement pilot process upgrades Measure result Implement and move on to the next project

Requirements for a successful kaizen program

Operating practices Total involvement training

Kaizen And Deming



The similarity in Kaizen and Deming Principles are Never ending quality improvement Responsibility of management Process oriented approach Total quality attainment Striving for long term and sustained benefit PDCA cycle Importance of communication, development & involvement of employees

Lowers costs

BENEFITS OF KAIZEN
(Non- Manufacturing Concern)

Immediate Results Reduces waste Energizes Employees Increase Productivity

Pit Falls In Kaizen


Resistance to change
Lack of proper procedure to implement Too much suggestion may lead to confusion and

time wastage

Companies Using Kaizen


Maruti Suzuki: One Operator, One Step Reduction initiative helped Maruti to reduce 21,500 steps from worker walks in FY13
TATA Motors: Kaizen Sheet helped to reduce customer complaints Birla Plus Cement, an Aditya Birla Group Company: Kaizen as part of integrated continuous improvement model broadly deployed across Businesses

Ford: Sigma Kaizen events


Intel Corporation - Fab 23: Training staff in doing Kaizen. Using Kaizen to improve all operations

Companies Using Kaizen

Delphi Automotive: Key success factors for


lean and Kaizen implementation

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

Conclusion
Kaizen is based on a belief that continual improvement can be
brought about by a continuing series of small changes.

Even if there is a culture of big innovative changes it is argued


that these will still need to be supplemented by continuing small step changes.

Indeed the whole idea of continuous improvement is that it can


eliminate the need for any large scale quantum shifts.

Thank you

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