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Kaizen ~ Continuous Process Improvement (Cpi)

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Using Kaizen to optimise process performance & sustain the incremental Improvements

Using Kaizen to optimise process performance & sustain the incremental Improvements

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  • 1. Kaizen / Continuous Process Improvement (CPI)
    Using Kaizen to optimise process performance & sustain the incremental Improvements
    Anand Subramaniam
  • 2. 2
    “The difference between 'involvement' and 'commitment' is like an eggs-and-ham breakfast: the chicken was 'involved' - the pig was 'committed'.”
    - Unknown
  • 3. Kaizen vs. CPI
  • 4. Continuous Improvement Cycle
    4
    Key Measures
    Vision, Mission & Strategies
    Management Review
    Lower-level Objectives
    Prioritise improvement
    Data Analysis
    • Customer complaints
    • 5. Internal audits
    • 6. Supplier issues
    • 7. Employee suggestions
  • CPI – Tools / Concepts / Techniques
    5
    Variation
    DMAIC
    DPMO
    Six Sigma
    ISO 9000
    Lean
    Takt
    Andon
    Pull
    Control Panels
    QFD
    SIPOC
    Value Stream Map
    FMEA
    Value Stream
    Forms of Muda
    Kaizen
    Poka Yoke
    5 S’s
    Cellular Manufacturing
    TQM
    Five Whys
    DFSS
    CPK
    PDSA
    NSPS
    Jidoka
    Systems
    Thinking
    Control Chart
    Process
    Capability
    Kanban
    Continuous Flow
  • 8. Comparison of CI Initiatives
    The differences depend on how they drive improvement.
    6
  • 9. CPI – Lean Six Sigma
    7
    Define
    5S Event
    Six Sigma Project
    Kaizen Event
    Measure
    Workplace Organisation
    Waste
    Variations
    Analyse
    Improve
    Rapid Implementation
    Control
    Problem Solving
  • 10. Continuous Improvement - Kaizen
    8
    DO
    DO
    DO
    PLAN
    PLAN
    PLAN
    CHECK
    CHECK
    CHECK
    ACT
    ACT
    ACT
    Performance
    Standardise & Sustain
    Kaizen Event
    Standardise & Sustain
    Kaizen Event
    Standardise & Sustain
    Kaizen Event
    Kaizen Event
    Time
  • 11. Kaizen – Reduction in Non-Value Add
    9
    Before Kaizen
    The kaizen mindset focuses on small, incremental yet frequent improvements to make changes to non value added processes.
    Value Add
    Kaizen 1
    Non Value Add
    Kaizen 2
    Kaizen 3
    Kaizen
    Kaizen
    Kaizen
    Measurable Improvements over time
  • 12. Kaizen vs. CPI
    10
    Process
    Breakthrough
    Process Performance
    Continuous
    Improvement
    Time
  • 13. Kaizen vs. CPI
    11
    Process Improvement Project Implemented
    • Data driven methodology to magnify impact of process improvement
    • 14. Apply control techniques to eliminate erosion of improvements
    • 15. Standardiseimprovements for improved maintenance of critical process parameters
    Savings
    Maintenance of Process Performance
    Time
    CPI Project
    CPI projects emphasise control and long term maintenance
    Savings
    Time
    • Kaizen uses small teams to optimise process performance by implementing incremental change
    • 16. Apply intellectual capital of team members intimate with process
    • 17. Kaizen Projects emphasise Incremental Improvements
    Kaizen
    CPI
    Savings
    Time
  • 18. 12
    “When I am working on a problem I never think about beauty. I only think about how to solve the problem. But when I have finished, if the solution is not beautiful, I know it is wrong."
    - Buckminster Fuller
  • 19. 13
    Good Luck
    http://www.linkedin.com/in/anandsubramaniam