Kaizen

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Kaizen

  1. 1. KAIZEN- AN INTRODUCTION <ul><li>Masaaki Imai is known as the developer of Kaizen. </li></ul><ul><li>改 ('kai') KAI means 'change' or 'the action to correct'. </li></ul><ul><li>善 ('zen') ZEN means 'good' </li></ul>
  2. 3. <ul><li>So basically kaizen is small incremental changes made for improving productivity and minimizing waste. </li></ul><ul><li>Kaizen has three main principles: </li></ul><ul><li>• Consider the process and the results! • 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. </li></ul>
  3. 4. FEATURES OF KAIZEN <ul><li>Widely applicable – Can be used in both manufacturing and non-manufacturing environments </li></ul><ul><li>Highly effective & results oriented . Kaizen events will generate </li></ul><ul><li>quick results, Measurable results, Establish the baseline, and measure the change!!! </li></ul><ul><li>A Learning Experience – Every member of a Kaizen Team will walk away from the event learning something new! ! </li></ul><ul><li>Team based & cross functional – Team members can be from various functions of the business. Top management participation is encouraged. </li></ul>
  4. 5. THE STEPS OF KAIZEN ARE : A.) Select an Event B.) Plan an Event C.) Implement an Event D.) Follow-up to an Event
  5. 6. BENEFITS OF KAIZAN <ul><li>Kaizen Reduces Waste- like inventory waste, time waste, workers motion </li></ul><ul><li>Kaizen Improves space utilization, product quality </li></ul><ul><li>Results in higher employee moral and job satisfaction, and lower turn-over. </li></ul><ul><li>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. </li></ul>
  6. 7. Varieties of Kaizen Methods <ul><li>Individual Versus Teamed </li></ul><ul><li>Day-to-Day Versus Special Event </li></ul><ul><li>Process Level Versus Sub process Level </li></ul>
  7. 8. 5 ‘S’ in KAIZEN <ul><li>5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized. </li></ul><ul><li>To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following &quot;5S&quot; steps </li></ul><ul><li>Sorting keeping only essential items </li></ul><ul><li>Simplifying eliminates extra motion . </li></ul><ul><li>Sweeping keep the workplace clean </li></ul><ul><li>Standardizing standardized work practices </li></ul><ul><li>Sustaining maintaining and reviewing standards </li></ul>
  8. 9. PIT FALLS IN KAIZEN <ul><li>Resistance to change </li></ul><ul><li>Lack of proper procedure to implement </li></ul><ul><li>Too much suggestion may lead to confusion and time wastage </li></ul>
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