Scribd Logo
Upload

Welcome to Scribd!

  • 98 views

    PDCA & Kaizen For Kaizen Teams

    Uploaded by

    Abul Hasnat
    Kaizen refers to continuous improvement through small, incremental changes. The core principles of kaizen involve analyzing processes, eliminating waste, and making gradual improvements over time. Effective kaizen is achieved through kaizen teams and activities that follow the PDCA (plan-do-check-act) cycle. There is a difference between kaizen events, which address single issues over a short time period, and broader kaizen which aims to continuously improve the overall value stream. Standard tools like fishbone diagrams, 5 whys, and statistical process control charts are used to analyze problems and identify root causes.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    PDCA & Kaizen For Kaizen Teams

    Uploaded by

    Abul Hasnat
    98 views25 pages
    Kaizen refers to continuous improvement through small, incremental changes. The core principles of kaizen involve analyzing processes, eliminating waste, and making gradual improvements over time. Effective kaizen is achieved through kaizen teams and activities that follow the PDCA (plan-do-check-act) cycle. There is a difference between kaizen events, which address single issues over a short time period, and broader kaizen which aims to continuously improve the overall value stream. Standard tools like fishbone diagrams, 5 whys, and statistical process control charts are used to analyze problems and identify root causes.

    Original Description:

    Pdca kizen teams

    Original Title

    6. PDCA & Kaizen for Kaizen teams

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Kaizen refers to continuous improvement through small, incremental changes. The core principles of kaizen involve analyzing processes, eliminating waste, and making gradual improvements over time. Effective kaizen is achieved through kaizen teams and activities that follow the PDCA (plan-do-check-act) cycle. There is a difference between kaizen events, which address single issues over a short time period, and broader kaizen which aims to continuously improve the overall value stream. Standard tools like fishbone diagrams, 5 whys, and statistical process control charts are used to analyze problems and identify root causes.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    98 views25 pages

    PDCA & Kaizen For Kaizen Teams

    Uploaded by

    Abul Hasnat
    Kaizen refers to continuous improvement through small, incremental changes. The core principles of kaizen involve analyzing processes, eliminating waste, and making gradual improvements over time. Effective kaizen is achieved through kaizen teams and activities that follow the PDCA (plan-do-check-act) cycle. There is a difference between kaizen events, which address single issues over a short time period, and broader kaizen which aims to continuously improve the overall value stream. Standard tools like fishbone diagrams, 5 whys, and statistical process control charts are used to analyze problems and identify root causes.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 25

    Kaizen

    PDCA

    Performance Policy

    Kaizen Teams

    Kaizen Formats
    What is Kaizen?

    Kaizen is a basic scientific analysis in which you analyze (or take


    apart) the elements of a process or system to understand how it
    works.

    Lean Production is founded on the idea of kaizen – the small,


    gradual, incremental changes applied over a long period that add up
    to a major impact on business result.
    You should Know the following to fully Understand
    and do Kaizen

    The right Spirit of kaizen


    Ten basic principles for Improvement

    1. Throw out all of your fixed ideas about how to do things.


    2. Think of how the new method will work-not how it won’t.
    3. Don’t accept excuses. Totally deny the status quo.
    4. Don’t seek perfection. A 50-percent implementation rate is fine as long
    as it’s done on the spot.
    5. Correct mistakes the moment they’re found.
    6. Don’t spend a lot of money on improvement.
    7. Problems give you a chance to use your brain.
    8. Ask “why” at least five times until you find the ultimate cause.
    9. Ten people’s ideas are better than one person’s.
    10. Improvement knows no limit.
    Kaizen Activities
    Difference between
    Kaizen and Kaizen Event?
    There is a difference between Kaizen and Kaizen-Event

    Kaizen Event
    Kaizen events are activities handled by Kaizen teams to address
    single subject / area. They are usually one time only affairs.

    Kaizen
    Kaizen is word of Continuous Improvement incorporated as a
    normal day by day approach to the improvement of the entire
    value stream and in the mind of the people driving performance.
    Chracterizing Kaizen Activity, Event or Blitz?

    • Is a team activity (Kaizen Teams) aimed at rapid use of lean methods to


    eliminate production waste in a particular area of the shop floor related
    mostly to Tools and Systems.
    • A kaizen event must be carefully prepared, well coordinated, and
    thoroughly followed-up in order to be successful.
    • Many successful events are planned for shorter period such as: Half day,
    one day or 2 days
    Definng Point and Flow Kaizen Event?
    There is a difference between Flow and Point Kaizen Event

    Flow Kaizen
    Value Stream Improvement related to information and materials
    flow “Pull”.

    Point Kaizen
    Incremental Improvement related to waste elimination that
    impact resources utilization (people waiting, resources, excess
    motions, space, unnecessary activities)
    What might Kaizen Activities cover
    Kaizen Activities

    1. Covers daily deviations to maintain level, flow, pull and standardized


    work reliability as targeted such as:

    • Quality at the Source • SOP


    • Order Changeover • Balancing
    • Point of Use System • Minutes Produced
    • Kanban Flow • Rework & Rejects
    • WIP • Etc.

    2. Covers Long term Kaizen costing and new core goals set by top
    management
    Kaizen Activities are achieved through

    PDCA
    Plan-Do-Check-Act

    The Wheel of Problem Solving


    PDCA Chart Details
    The wheel of Problem Solving
    1 - Plan 2 - Do
    1. Clearly Identify the problem 1. Ensure requirements are available
    2. Break the problems into small Job using fishbone 2. Test out the knowledge and
    3. Simplify the fishbone and isolate possible problems understanding of relevant people prior
    4. Assess using IE or diagnosis tools to trial
    5. Simulate the results and analyze consequences 3. Implement the new solution
    6. Identify the root cause through 5 Whys
    7. Brainstorming session with concerned people
    8. Create hypotheses to test new ideas and keep trying till
    solution is satisfactory
    9. Set and Plan the requirements for new idea

    3 - Check 4 - Act
    1. Ensure new solution is fully implemented as designed 1. Identify and Plan adjustments
    2. Assess & compare the results using IE and diagnosis 2. Implement adjustments
    tools 3. Follow Up & define effect on
    3. Analyze what is blocking full achievement management systems
    4. Repeat the steps listed under “DO” 4. Standardize the solution
    Focus and Role of Problem Solving

    Who does what? When and How?


    Categorizing Problems

    There are 2 categories of problems:

    1. Problems caused by practices and processes due to workers and can be


    solved through workers and supervisors or with the immediate support of
    staffs

    2. Problems caused by management systems and support concept or / and


    other processes should be reported to Kaizen Board to troubleshoot by
    relevant management
    Performance Policy

    Daily improvement via PDCA


    Formulating Core Kaizen Teams

    Kaizen (Continuous Improvement) Teams

    Kaizen Teams are composed as per the needs of each company


    by process and by flow or point kaizen. Also, some other
    companies are identified the kaizen teams as per the needs of the
    standardized tools and practices.
    Kaizen Team - Roles and Responsibilities

    The roles and responsibilities of the members are to engage only


    when a long term goal is set or as per the needs of management
    when a standardized work keep deviating this means a new
    method should be analyzed and defined.
    Kaizen Team Leader

    Team members will select their own team leaders, which his role
    is to plan the kaizen activities, to guide, develop, monitor and
    implement the improvement.
    Kaizen Team – Method of Work

    Kaizen Teams will follow the Kaizen Event scientific approach


    in logical approach using fishbone, 5whys and etc.

    1. Event is planned on Kaizen Event worksheet


    2. Event is planned using PDCA Approach. See next slides
    Other Formats used by Kaizen Teams
    To analyze
    Fiashbone Structure
    5 Whys
    Root Cause Analysis
    SPC Charts to Analyze problems
    Line Graph

    DCG 23
    Pareto Chart

    DCG 24
    Pie Chart

    DCG 25

    You might also like