What is Kaizen?
Kaizen is a Japanese word meaning Gradual,
Orderly, Continuous Improvement.
1993 edition of the New Shorter Oxford English
Dictionary contained the word “Kaizen”. And
defines Kaizen as
“ Continuous improvement of working practices,
personal life, social life & home life as a
business philosophy.”
What is Kaizen?
Kaizen means:
Kai :- Change
Zen :- For Betterment
When applied to the work place, kaizen means
continuing improvement involving everyone
managers & workers alike.
What is Kaizen?
Kaizen leads to high productivity, quality & good
environment conditions, low cost & on time
delivery.
Kaizen is a culture of sustained continuous
improvement focusing on eliminating waste in all
system & processes of an organization.
Gemba Kaizen
Gemba History
In business, three major activities directly
related to earning profits
1. Developing (design table, lab)
2. Producing (shop floor)
3. Selling (retail outlet, service centers)
In short “Gemba” means actual sites of these
three major activities.
Gemba Kaizen
Gemba History
Jan 1995, when earthquakes shook Kobe, T.V. reporters
at the scene referred to themselves as “reporting from
Gemba”- in background houses in flames or collapsed
elevated highways were shown.
In business, the value adding activities happen in
Gemba.
Joop Bokern, one of the first Kaizen consultant in
Europe, said whenever he visited a Japanese Co., he
had a rule of thumb to determine whether the company
was good or not. If he heard the word Kaizen in first 5
minutes & word Gemba in next 10 minutes,
he concluded that must be a good company.
Kaizen
Objectives of Kaizen
Kaizen is related with day to day activities
To eliminate MUDA, MURA, MURI.
To improve productivity.
To reduce cost
To make operation standardization.
To improve quality.
To improve on time delivery.
Kaizen
Muda (Waste)
There are seven types of wastages
Over production
Transport (transport of raw- material)
Waiting
Process (process which do not add value)
Movement
Stock (stores, warehouse)
Inferior Production/ Rework/ Rejection.
Kaizen
Muda (Waste)
S. Waste Nature of waste How to eliminate
No. Category
1. WIP Stocking items not immediately Streamline inventory.
needed
2. Rejection Producing defective products Reduce rejection
3. Facilities Idle M/C, breakdowns, excessive Increase capacity
set up time utilization ratio.
4. Expenses Over investing for required output Curtail expenses
5. Indirect Excessive personnel due to poor Assign job efficiently.
labour indirect labour system.
Kaizen
Muda (Waste)
S. Waste Nature of waste How to eliminate
No. Category
6. Design Producing products with more Reduce costs
functions than necessary
7. Talent Employing people for jobs that Institute labour saving or
can be mechanized or assigned labour maximization
to less skilled people. Measurers.
8. Motion Not working according to work Improve work standards.
standard
9. New Slow start in stabilizing the Shift to full-time
product production of a new product. Production more quickly.
run-up
Kaizen
Principles & Concept
To identify
Muda means non-value adding activities.
Mura means inconsistencies.
Muri means irregularities in an activity.
To find out root cause for above.
To take countermeasures on root causes for
continuous improvement.
Kaizen
Implementation
Following steps are used to implement Kaizen
To generate Kaizen ideas.
To evaluate & examine ideas.
To find out root causes using why-why
analysis.
To implement Kaizen idea.
To deploy Kaizen idea horizontally.
To present all the kaizen activity in suitable
format.
Kaizen
Kaizen is to Eliminate MUDA
1. Eliminate MUDA related to :
1. Manpower
2. Machines & Equipments
3. Means
4. Quality Control
5. Material & Parts
2. Improvement of safety.
MUDA Related to Manpower
Monitoring (machines)
Walking & Moving (layout)
Conveyance (materials)
Searching
Irresolution (methods)
Handling (products)
Motion
Reworking
Idling
MUDA Related to Machines &
Equipments
Space and transportation
Efficiency
Leakage of oil
Minor stoppage
Cleaning (Prevention)
Leakage of air & energy
Lights on
MUDA Related to Means
Congestion (bottleneck process)
Inventories
Idling of machines
Set up of machines
Adjustments
Wrapping and unwrapping
MUDA Related to Quality
Control
Production of defectives
Reworking
Fool proofing of automated machines
Absence of standards
Flaws caused by conveyance
Inspections
MUDA Related to Materials. &
Parts
Clamping with bolts
Number of parts
Deburring operations
Heavy weight materials. & parts
Expensive materials
Scrap slug
Improvement of Safety
Danger at rotating parts
Danger of being caught in moving machines
Danger of being cut
Danger of fall
Danger of falling objects
Danger of collision
Danger related to handling
Danger at restarting the machine
Improvement of Safety
Danger of electric shock
Danger of accidents by toxic substances
Danger of explosion
Danger of high temperature
Danger related to work done by inexperienced
persons.
Danger from the absence of an established method
of use.
Danger from absence of dangerous zone signs.
Kaizen
Question to Generate Kaizen
Can I reduce the strainIdeas
in the operation?
Can this improvement be applied else where?
Is there an alternative way to do it?
Can this be reduced?
Can this be increased?
How can I identify the defect at source?
What are the non-value adding operations?
Can this be done in a faster, cheaper, safer, & easier
way?
Can I reduce the variations?
Kaizen
Seven Tools to Identify & Solve the Problem
Causes and effect diagram.
Check sheet
Pareto chart
Flow chart
Brain storming
Histogram
Control chart
Kaizen
Ask why 5 times & then how?
Q.1 Why are you throwing saw dust on the floor?
A. “Because the floor is slippery and unsafe.”
Q.2 Why is it slippery and unsafe?
A. “Because there is oil on it.”
Q.3 Why is there oil on it?
A. “Because the machine is dripping.
Q.4 Why is it dripping?
A. “Because oil is leaking from the oil coupling.”
Q.5 Why is it leaking?
A. “Because the rubber lining inside the coupling is worn
out.”
Kaizen
Ishikawa ( fishbone) diagram
Diagram developed by Professor Kaoru
Ishikawa to show, causes (process) & the effect
(result).
One of the basic tool of problem solving.
Cause Effect
Kaizen
Practical part of Kaizen
Form a small group of 5 to 7 people.
Assign specific area for identification of Kaizen idea
Use seven tools to identify root cause and to solve the
problem.
Find out counter measure.
Implement Kaizen idea.
Assess the results.
Decide horizontal deployment.
Write the details in Kaizen-sheet.
Asses the knowledge of participants through assessment
feedback form.
Kaizen
Kaizen sheet
Please see the photograph of
Kaizen sheet board.
Ka
iz
en
A
ss
es
sme
ntFo
rmtoa
ss
es
sth
etra
in
ee
.
1. Whichof thefollow ing descriptionbest suitstheKaize
nmoveme
nt?
A. Zenindustrial im provem ents
B. Zerointe nsityinitiative
C. Zeroinve stm entim provem ent
D. All of theabove
E. Noneof theabove.
2. Kaize
n activi tiescanbeundertake
natthe
A. Toplinem anagem ent
B . Middlelinem anagers
C. Front linem anagem ent
D . Noneof theabove
E. All of theabove
3. For under takingKaizenactivitiesapersonmust be:
A.Qualitype rsonnel
B. Productionpe rsonne l
C. D eve
lopm e ntpe rsonne l
D.Anyoftheabove
E.None oftheabove .
4.Kaize ninJapane sem eans:
A.Changeforbe tte
rm e
nt
B.Teamwork
C.Costre duction
D .Noneof theabove .
E. All of theabove .
5. ‘Cause & effect’ diagram is also known as:
A. Kobayashi diagram
B. Kiwi diagram
C. Ishikawa diagram
D. None of the above
E. All of the above.
6. ‘Fish bone’ diagram is normally used for:
A. Root cause analysis.
B. Cost reduction
C. Calculating rejection ppm
D. None of the above
E. All of the above
7. Which is of the following is an important aspect in Kaizen:
A. Sharing
B. Openness
C. Team work
D .None of the above
E. All of the above
Thank you!
