1. Characteristics of
Japanese Production Systems

2. What is Industry ?
Input Output
Industry
Man-power Products
Machines Services
Materials
Methods Technology
Skill
(4M’s)
KM 2

3. Evaluation of the output ?
Q, C, D
Input Output
Industry
Q: Quality
C: Cost
KAIZEN
D: Delivery action
KM 3

4. KAIZEN is a feedback
Input Output
Industry
KAIZEN
action
KAIZEN is a corrective action
KM 4

5. Productivity: 1 net per min.
KM 5

6. KM 6

7. Productivity: 5 nets per min. with 2 workers
KM 7

8. A selection of better means or
a change of current method
for achieving an objective.
Can you think of a better
method to pack oranges?
KM 8

9. Productivity: 5 nets per min. with 1 worker KM 9

10. KAIZEN is
a continuous improvement
Continuous = again and again
KM 10

11. Suggestion System
vs.
KAIZEN Suggestion System
KM 11

12. Suggestion System
You suggest your ideas, and I will examine
them and implement some of your ideas
later.
KM 12

13. Suggestion System Concept
KM 13

14. KAIZEN Suggestion System
Implemented KAIZEN ideas must be
submitted
KM 14

15. Suggestion System
Workers’
responsibility Management responsibility
Idea
generation
Workers’ responsibility Management
responsibility
KAIZEN Suggestion System
KM 15

16. Suggestion System
Propose improvement ideas for any
activity in the company.
KAIZEN Suggestion System
Propose only improvement ideas which
will improve your own work.
KM 16

17. KAIZEN Memo KM 17
1

18. AOTS KAIZEN
KM 18

19. Reward
For an excellent KAIZEN, a large amount of reward is
given (5000 yen, 10000 yen, 50000 yen)
KM 19

20. Award Payment for Each KAIZEN
Suggestion (2008)
0 50 100 150 200
0 18
1-99 24
100-299 110
Jpn Yen
300-499 109
500-999 163
1000-2999 83
3000-4999 11
Average 385 yen
5000+ 10
Surveyed 528 companies
KM 20

21. 2008
Among (527) companies,
Employees who suggested at lease one idea
Total number of employees
74.4%
Implemented suggestions
All suggestions
88.7% KM 21 1

22. Different styles of change
1. Small change --- By individual effort, a better way
of proceeding a job is considered.
(KAIZEN) (Idea creation)
2. Medium change --- By group effort, a better way is
proposed by following
(Small group predetermined steps (or rule).
activities)
3. Big change --- By investments in new technology or
equipment, dramatic alterations are
(Innovation) achieved.
2
KM 22

23. Process
Change
Tomato Juice KM 23

24. Tomato Juice
Process Material
Change Change
Input Output
Industry
Man-power
Machines
Materials
Methods KAIZEN
action
(4M’s)
2
KM 24

25. Two Attitudes
Management Breakthrough
Staff
Floor people Status quo
KM 25

26. Japanese firms
Management
Staff
Floor people
Non-Japanese firms
Management
Staff
Floor people
KM 26

27. KAIZEN is a Japanese word.
Contents

28. Definition of KAIZEN
1. better method for achieving
an objective.
2. An accumulation of small changes.
Bricks
Bricks
3. A corrective action
under constraints.

29. Kaizen Objectives
 Quality
 Cost
 Delivery
(QCD)

30. 5 S for Kaizen
1. Simple
2. Small
3. Smooth
4. Slim
5. Smart

31. Kaizen PQCDSEM
 P-Productivity
 Q-Quality
 C-Cost
 D- Delivery
 S-Safety
 E-Environment
 M-Moral

32. Raise the
Lower the table
table
A corrective action under constraints

33. You cannot change the table
height.

34. After KAIZEN
Easy to
work.
Footstool 1

35. You must open 3 doors to start KAIZEN
(Problem
Identification)
Implementation
Problem solving
(Idea generation) 3

37. KAIZEN by “Elimination”
Why are shoe box doors needed?
Before After 1

38. KAIZEN by “Elimination”
Why are shoe box doors needed?
Before After 1

39. KAIZEN by “Reduction”
Before 1

40. KAIZEN by “Reduction”
Side lines of the
zebra zone are
removed.
Before
After
1

41. KAIZEN by “Change”
Before
1

42. KAIZEN by “Change”
The hollow about the key hole
smoothes the key movement.
Before After
1

43. Thank You