Kaizen thinking vs kaikaku thinking
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Kaizen thinking vs kaikaku thinking

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Contrast and Compare Kaikaku vs Kaizen Thinking

Contrast and Compare Kaikaku vs Kaizen Thinking

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    Kaizen thinking vs kaikaku thinking Kaizen thinking vs kaikaku thinking Presentation Transcript

    • Contrast and Compare KAIZEN thinking vs KAIKAKU thinking vs Created by Todd McCann A Quote from Taiichi Ohno “ Where there is NO Standard there can be NO KAIZEN” We Serve the GEMBAWe Teach Leaders to “Learn to See” and “Serve the Gemba”
    • A Picture of the thinking required for KAIKAKU Contrast and Compare KAIZEN thinking to KAIKAKU thinking VS Kaizen Thinking Kaikaku Thinking Incremental Change <> Tortoise Velocity Step Change <> Rocket Velocity A Picture of the thinking required for KAIKAKU Contrast and Compare KAIZEN thinking to KAIKAKU thinking PDCA SDCA from Honorable Imai Masaaki PDCA and SDCA Systematic KAIZEN Improvement Pathway Created by: Todd McCann (from Gemba KAIZEN Masaaki Imai) PDCA and SDCA Step Change KAIKAKU Pathway Created by: Todd McCann (from Gemba KAIZEN Masaaki Imai) The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009 Rev: 3 The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009 Rev: 3 (Plan – Do – Check – Act with Standardize – Do – Check – Act) (Plan – Do – Check – Act with Standardize – Do – Check – Act) Measure Measure LS L P rocess D ata 3456.5 Unit 1 July 0 8 MWt 8 hr avg. LSL USL 3 45 8 W ith in O v erall Unit 1 J uly 0 8 MWt 8 hr av g. LS L USL 3458 A P T arget * USL S am ple M ean S am ple N S tD ev (Within) S tD ev (O v erall) 3457.5 3456.77 693 0.152393 0.354484 P otential (Within) C apability Cp C PL C PU C pk 1.09 0.59 1.59 0.59 A P KAIZEN LS L T a rge t USL P roce ss D a ta 3456.5 * 3457.5 W ith in O v er all P ote ntia l (Within) C a pa bility A ct P la n C C pk 1.09 Cp 1.09 O v erall C apability S a m ple M e a n 3456.77 Pp 0.47 S a m ple N 693 C PL 0.59 PPL PPU P pk 0.26 0.68 0.26 A ct P la n S tD e v (W ithin) S tD e v (O v e ra ll) 0.152393 0.354484 C PU C pk 1.59 0.59 C pm * C C pk 1.09 C O v e ra ll C a pa bility O bserv ed P erform ance P P M < LS L PPM > USL P P M T otal 225108.23 1443.00 226551.23 3456.0 P P M < LS L PPM > USL P P M T otal 3456.4 3456.8 E xp. Within P erform ance 37235.72 0.88 37236.60 3457.2 3457.6 P P M < LS L PPM > USL P P M T otal 3458.0 E xp. O v erall P erform ance 221596.02 19978.92 241574.93 3458.4 C D Pp PPL PPU P pk C pm 0.47 0.26 0.68 0.26 * D C heck Do 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 C heck Do Measure O bserv e d P e rform a nce P P M < LS L 225108.23 E xp. W ithin P e rform a nce P P M < LS L 37235.72 E xp. O v e ra ll P erform a nce P P M < LS L 221596.02KAIZEN Improvements PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T ota l 226551.23 P P M T ota l 37236.60 P P M T ota l 241574.93 Unit 1 July 0 8 MWt 8 hr avg. P rocess D ata LS L USL 3 45 8 W ith in A P KAIKAKU Improvement LS L 3456.5 O v erall T arget * P otential (Within) C apability USL 3457.5 S am ple M ean S am ple N S tD ev (Within) S tD ev (O v erall) 3456.77 693 0.152393 0.354484 Cp C PL C PU C pk 1.09 0.59 1.59 0.59 A ct P la n C C pk 1.09 O v erall C apability Pp PPL PPU 0.47 0.26 0.68 KAIZEN C P pk 0.26 D C pm * A P 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bserv ed P erform ance E xp. Within P erform ance E xp. O v erall P erform ance C heck Do KAIZEN P P M < LS L 225108.23 P P M < LS L 37235.72 P P M < LS L 221596.02 PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 A ct P la n VS Measure A S A ct Unit 1 July 0 8 MWt 8 hr avg. LSL USL 3 45 8 A P S ta n d a rd iz e C D P rocess D ata W ith in S LS L 3456.5 O v erall T arget USL S am ple M ean S am ple N S tD ev (Within) * 3457.5 3456.77 693 0.152393 P otential (Within) C apability Cp C PL C PU 1.09 0.59 1.59 A ct P la n C D C heck Do A C pk 0.59 S tD ev (O v erall) 0.354484 C C pk 1.09 O v erall C apability C heck Do A ct Pp 0.47 PPL 0.26 PPU 0.68 C S ta n d a rd iz e P pk C pm 0.26 * D KAIZEN 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bserv ed P erform ance P P M < LS L PPM > USL 225108.23 1443.00 E xp. Within P erform ance P P M < LS L PPM > USL 37235.72 0.88 E xp. O v erall P erform ance P P M < LS L PPM > USL 221596.02 19978.92 C heck Do P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 C D A S C heck Do A ct S ta n d a rd iz e Measure C D Unit 1 July 0 8 MWt 8 hr avg. C heck Do Measure LSL USL 3 45 8 P rocess D ata W ith in LS L 3456.5 O v erall T arget * P otential (Within) C apability USL 3457.5 Cp 1.09 S am ple M ean 3456.77 S am ple N 693 C PL 0.59 S tD ev (Within) 0.152393 C PU 1.59 Unit 1 J uly 0 8 MWt 8 hr av g. P C pk 0.59 S tD ev (O v erall) 0.354484 A C C pk 1.09 O v erall C apability Pp 0.47 PPL 0.26 LS L USL 3458 PPU 0.68 P roce ss D a ta W ith in P pk 0.26 C pm * A ct P la n LS L T a rge t 3456.5 * O v er all P ote ntia l (Within) C a pa bility S USL 3457.5 A Cp 1.09 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 S a m ple M e a n 3456.77 S a m ple N 693 C PL 0.59 O bserv ed P erform ance E xp. Within P erform ance E xp. O v erall P erform ance C PU 1.59 P P M < LS L 225108.23 P P M < LS L 37235.72 P P M < LS L 221596.02 S tD e v (W ithin) 0.152393 REFORM with KAIKAKU PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 C pk 0.59 P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 S tD e v (O v e ra ll) 0.354484 C C pk 1.09 C D KAIZEN A ct S ta n d a rd iz e O v e ra ll C a pa bility Pp PPL 0.47 0.26 PPU 0.68 C heck Do P pk C pm 0.26 * C D Difficulty Increases 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 C heck Do O bserv e d P e rform a nce P P M < LS L 225108.23 E xp. W ithin P e rform a nce P P M < LS L 37235.72 E xp. O v e ra ll P erform a nce P P M < LS L 221596.02 PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T ota l 226551.23 P P M T ota l 37236.60 P P M T ota l 241574.93 “Smaller” GAP Harder Change “Small” GAP A S Hard Change S A ct S ta n d a rd iz e A C D A ct S ta n d a rd iz e C heck Do “Large” GAP Easy Change C D C heck Do TIME TIME
    • PDCA and SDCA Systematic KAIZEN Improvement Pathway Created by: Todd McCann (from Gemba KAIZEN Masaaki Imai) The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009 Rev: 3 (Plan – Do – Check – Act with Standardize – Do – Check – Act) Measure Unit 1 July 0 8 MWt 8 hr avg. LS L USL 3 45 8 P rocess D ata W ith in LS L 3456.5 O v erall T arget * KAIZEN P otential (Within) C apability USL 3457.5 P Cp 1.09 A S am ple M ean 3456.77 S am ple N 693 C PL 0.59 C PU 1.59 S tD ev (Within) 0.152393 C pk 0.59 S tD ev (O v erall) 0.354484 C C pk 1.09 O v erall C apability Pp 0.47 PPL PPU P pk 0.26 0.68 0.26 A ct P la n C pm * 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bserv ed P erform ance E xp. Within P erform ance E xp. O v erall P erform ance P P M < LS L PPM > USL P P M T otal 225108.23 1443.00 226551.23 P P M < LS L PPM > USL P P M T otal 37235.72 0.88 37236.60 P P M < LS L PPM > USL P P M T otal 221596.02 19978.92 241574.93 C D C heck Do MeasureKAIZEN Improvements Unit 1 July 0 8 MWt 8 hr avg. LS L T arget P rocess D ata 3456.5 * LS L USL 3 45 8 W ith in O v erall P otential (Within) C apability A P USL 3457.5 S am ple M ean S am ple N S tD ev (Within) S tD ev (O v erall) 3456.77 693 0.152393 0.354484 Cp C PL C PU C pk 1.09 0.59 1.59 0.59 A ct P la n C C pk 1.09 O v erall C apability Pp 0.47 PPL 0.26 PPU 0.68 C P pk 0.26 D C pm * 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bserv ed P erform ance E xp. Within P erform ance E xp. O v erall P erform ance C heck Do KAIZEN P P M < LS L 225108.23 P P M < LS L 37235.72 P P M < LS L 221596.02 PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 Measure A S A ct S ta n d a rd iz e P Unit 1 July 0 8 MWt 8 hr avg. LS L P rocess D ata 3456.5 LS L USL 3 45 8 W ith in A O v erall T arget * USL S am ple M ean S am ple N 3457.5 3456.77 693 P otential (Within) C apability Cp C PL C PU 1.09 0.59 1.59 A ct P la n C D S tD ev (Within) 0.152393 C pk 0.59 S tD ev (O v erall) 0.354484 C C pk 1.09 O v erall C apability Pp PPL 0.47 0.26 C heck Do C PPU 0.68 P pk C pm 0.26 * D KAIZEN 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bserv ed P erform ance P P M < LS L PPM > USL 225108.23 1443.00 E xp. Within P erform ance P P M < LS L PPM > USL 37235.72 0.88 E xp. O v erall P erform ance P P M < LS L PPM > USL 221596.02 19978.92 C heck Do P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 A S A ct S ta n d a rd iz e Measure C D Unit 1 July 0 8 MWt 8 hr avg. C heck Do LS L USL 3 45 8 P rocess D ata W ith in LS L 3456.5 O v erall T arget * P otential (Within) C apability USL 3457.5 Cp 1.09 S am ple M ean 3456.77 S am ple N 693 C PL 0.59 C PU 1.59 S tD ev (Within) 0.152393 P C pk 0.59 S tD ev (O v erall) 0.354484 A C C pk 1.09 O v erall C apability Pp 0.47 PPL 0.26 PPU 0.68 P pk 0.26 C pm * A ct P la n O bserv ed P erform ance P P M < LS L PPM > USL 225108.23 1443.00 3456.0 P P M < LS L PPM > USL 3456.4 3456.8 E xp. Within P erform ance 37235.72 0.88 3457.2 3457.6 P P M < LS L PPM > USL 3458.0 E xp. O v erall P erform ance 221596.02 19978.92 3458.4 A S P P M T otal 226551.23 P P M T otal 37236.60 P P M T otal 241574.93 C D KAIZEN A ct S ta n d a rd iz e C heck Do C D Difficulty Increases C heck Do “Smaller” GAP Harder Change “Small” GAP A S Hard Change A ct S ta n d a rd iz e C D C heck Do “Large” GAP Easy Change TIME
    • PDCA and SDCA Step Change KAIKAKU Pathway Created by: Todd McCann (from Gemba KAIZEN Masaaki Imai) The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009 Rev: 3 (Plan – Do – Check – Act with Standardize – Do – Check – Act) Measure U ni t 1 J ul y 0 8 MWt 8 hr av g. LS L USL 3458 A P LS L T a rge t USL P roce ss D a ta 3456.5 * 3457.5 W ith in O v er all P ote ntia l (Within) C a pa bility A ct P la n C p 1. 09 S a m ple M e a n 3456.77 S a m ple N 693 C PL 0. 59 C PU 1. 59 S tD e v (W ithin) 0.152393 C pk 0. 59 S tD e v (O v e ra ll) 0.354484 C C pk 1. 09 C O v e ra ll C a pa bility Pp PPL PPU P pk C pm 0. 47 0. 26 0. 68 0. 26 * D 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 C heck Do O bse rv e d P e rfo rm a nce E xp. W ithin P e rform a nce E xp. O v e ra ll P e rfo rm a nce P P M < LS L 225108.23 P P M < LS L 37235.72 P P M < LS L 221596.02 PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T o ta l 226551.23 P P M T ota l 37236.60 P P M T ota l 241574.93KAIKAKU Improvement KAIZEN A P A ct P la n C D C heck Do A S A ct S ta n d a rd iz e C D C heck Do Measure U ni t 1 J ul y 0 8 MWt 8 hr av g. LS L USL 3458 P roce ss D a ta W ith in LS L 3456.5 O v er all T a rge t * P ote ntia l (Within) C a pa bility USL 3457.5 C p 1. 09 S a m ple M e a n 3456.77 S a m ple N 693 C PL 0. 59 C PU 1. 59 S tD e v (W ithin) 0.152393 REFORM with KAIKAKU C pk 0. 59 S tD e v (O v e ra ll) 0.354484 C C pk 1. 09 O v e ra ll C a pa bility Pp 0. 47 PPL 0. 26 PPU 0. 68 P pk 0. 26 C pm * 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4 O bse rv e d P e rfo rm a nce E xp. W ithin P e rform a nce E xp. O v e ra ll P e rfo rm a nce P P M < LS L 225108.23 P P M < LS L 37235.72 P P M < LS L 221596.02 PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92 P P M T o ta l 226551.23 P P M T ota l 37236.60 P P M T ota l 241574.93 A S A ct S ta n d a rd iz e C D C heck Do TIME