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TRAINING ON            KAIZEN                                            SUKIN.S.SHETTYKAIZEN TRAINING   TOKAI RIKA MINDA ...
TOPICS TO BE DISCUSSED   INTRODUCTION OF KAIZEN   7 TYPES OF WASTES   WHY KAIZEN   8 KEY ELEMENTS OF KAIZEN CULTURE  ...
INTRODUCTION  KAIZEN MEANS CONTINUOUS IMPROVEMENT  IN JAPAN : KAIZEN                                    CHANGE FOR BETTER ...
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   4
TPS created KAIZEN based on DEMINGS cycle or PDSA cycleKAIZEN TRAINING         TOKAI RIKA MINDA INDIA PVT LTD         5
MAKE EVRYTHING AS SIMPLE ASPOSSIBLE BUT NOT SIMPLER                          -- ALBERT EINSTIENKAIZEN TRAINING   TOKAI RIK...
KAIZEN is a system of continuous improvement inquality, technology, process, company culture,productivity, safety and lead...
DEMINGS CYCLE KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   8
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   9
DEMINGS CYCLE  DEMINGS CYCLE or SHEWART CYCLE or PSDA  CYCLE found by EDWARDS DEMINGS AND WALTER  SHEWART      It is a con...
KAIZEN CYCLE      START         IDENTIFY WASTE      HERE                                           CELEBRATE  PLAN COUNTER...
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   12
7 types of wastes  KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   13
7 types of wastes               waste                  MUDA1. Over production -- Production more than required.2. WAITING ...
The foundation of Kaizen method consists of 5  founding methods :1. Team work2. Personal discipline3. Improved Morale4. Qu...
Improved Morale :Quality circles : Employee participation program.                 It consists of employees who meetperiod...
WHY KAIZEN 1. To eliminate waste in organization. 2. To increase productivity. 3. To improve quality 4. Customer satisfact...
8 KEY ELEMENTS OF KAIZEN CULTURE 1. KAIZEN MINDSET 2. CUSTOMER ORIENTATION 3. QUALITY CONTROL CIRCLES 4. SUGGESTION SYSTEM...
KAIZENMINDSET 1. EVERYTHING CAN & SHOULD BE IMPROVED 2. NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF    IMPROVEMENT. 3....
TOYOTA PRODUCTION SYSTEM- TPSTAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 1975.They visited several FORD ...
KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN ANDWEST          WEST                                           JAPAN 1. Deals ...
BENEFITS OF KAIZEN1. Savings in energy, material & others resources.2. Improvements in working environment.3. Improvements...
HOW TO IMPLEMENT KAIZEN            Employee identifies problem, waste or            an opportunity for improvement and    ...
The supervisor reviews the idea within            24hrs & encourages immediate action.             The employee implements...
Supervisor publishes the Kaizen and rewards      will be given        CELEBRATE THE SUCCESS OF YOUR KAIZENKAIZEN TRAINING ...
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   26
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   27
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   28
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   29
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   30
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   31
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Kaizen training

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Transcript of "Kaizen training"

  1. 1. TRAINING ON KAIZEN SUKIN.S.SHETTYKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 1
  2. 2. TOPICS TO BE DISCUSSED INTRODUCTION OF KAIZEN 7 TYPES OF WASTES WHY KAIZEN 8 KEY ELEMENTS OF KAIZEN CULTURE KAIZEN MINDSET TOYOTA PRODUCTION SYSTEM BENEFITS OF KAIZEN HOW TO IMPLEMENT KAIZENKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 2
  3. 3. INTRODUCTION KAIZEN MEANS CONTINUOUS IMPROVEMENT IN JAPAN : KAIZEN CHANGE FOR BETTER KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 3
  4. 4. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 4
  5. 5. TPS created KAIZEN based on DEMINGS cycle or PDSA cycleKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 5
  6. 6. MAKE EVRYTHING AS SIMPLE ASPOSSIBLE BUT NOT SIMPLER -- ALBERT EINSTIENKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 6
  7. 7. KAIZEN is a system of continuous improvement inquality, technology, process, company culture,productivity, safety and leadership.KAIZEN was developed in 1950 after the world war-IIby TAIICHI OHNO and SHIGEO SHINGO based onDEMINGS CYCLE or SHEWART CYCLE or PSDACYCLE. KAIZEN involves setting standards and then continuously improving those standardsKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 7
  8. 8. DEMINGS CYCLE KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 8
  9. 9. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 9
  10. 10. DEMINGS CYCLE DEMINGS CYCLE or SHEWART CYCLE or PSDA CYCLE found by EDWARDS DEMINGS AND WALTER SHEWART It is a continuous quantity improvement model consisting of a logical sequence of four repetition steps for continuous improvement and learning PLAN PLAN AHEAD FOR CHANGE. ANALYSE & PREDICT RESULTS DO EXCUTE THE PLAN TAKING SMALL STEPS. STUDY CHECK AND STUDY THE RESULTS ACT TAKE ACTION TO STANDARDIZE KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 10
  11. 11. KAIZEN CYCLE START IDENTIFY WASTE HERE CELEBRATE PLAN COUNTER MEASURES MAKE STANDARDREALITY CHECK VERIFY MAKE CHANGES KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 11
  12. 12. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 12
  13. 13. 7 types of wastes KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 13
  14. 14. 7 types of wastes waste MUDA1. Over production -- Production more than required.2. WAITING – Process delays idle time.3. TRANSPORTATION – Delay in material handling.4. EXCESS INVENTORY – Excess of raw material & tools for production.5. Motion – Actions of people or equipment that do not add value.6. OVER PROCESSING – Unnecessary stops or work elements or procedures.7. DEFECTIVE UNITS – Production of a part that is scrapped or require work.KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 14
  15. 15. The foundation of Kaizen method consists of 5 founding methods :1. Team work2. Personal discipline3. Improved Morale4. Quality circles5. Suggestions for improvement.KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 15
  16. 16. Improved Morale :Quality circles : Employee participation program. It consists of employees who meetperiodically to identify strength and weakness inproductionKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 16
  17. 17. WHY KAIZEN 1. To eliminate waste in organization. 2. To increase productivity. 3. To improve quality 4. Customer satisfaction. 5. Growth of the organization. 6. To eliminate any abnormalities & stopping of limits 7. Developing self personality. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 17
  18. 18. 8 KEY ELEMENTS OF KAIZEN CULTURE 1. KAIZEN MINDSET 2. CUSTOMER ORIENTATION 3. QUALITY CONTROL CIRCLES 4. SUGGESTION SYSTEM 5. DISCIPLINE IN WORKPLACE 6. SMALL GROUP ACTIVITIES 7. CO-OPERATIVE RELATIONS 8. TOTAL QUALITY MANGEMENT. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 18
  19. 19. KAIZENMINDSET 1. EVERYTHING CAN & SHOULD BE IMPROVED 2. NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF IMPROVEMENT. 3. IMAGINE THE IDEAL CUSTOMER EXPERIENCE AND STRIVE TO PROVIDE IT. 4. DON’T JUST CRITICIZE,SUGGEST AN IMPROVEMENT. 5. THINK OF HOW TO IMPROVE IT INSTEAD OF WHY IT CANT. 6. SET TARGET AND MOTIVATE YOURSELF TO ACHIVE IT. 7. USE COMPTETION TO AROUSE INTEREST. 8. DON’T LOOK FOR REWARDS. 9. GENERATE MORE QUESTIONS. 10. SAY YOURSELF I CAN DO IT KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 19
  20. 20. TOYOTA PRODUCTION SYSTEM- TPSTAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 1975.They visited several FORD motor company automotive plants in Michigan. But observed some methods not very effective . Then by chance they visited supermarket Piggly Wiggly. They were inspired how the products were re ordered and restocked goods. Reducing inventory by using just in time ( JIT) inventory system. Using easy methods to display their goods and arranging manpower only wherever required. They were doing good business with less investment.Main objective of TPS was :1. Reduce inventory by following JIT.2. Standardised work management.3. Continuous improvement.4. Lean manufacturing5. Customer satisfaction KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 20
  21. 21. KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN ANDWEST WEST JAPAN 1. Deals with quality of 1. Deals with quality of products. products 2. Manufacturer oriented 2. Customer oriented. 3. Product oriented aimed at 3. Process oriented aimed at detecting and eliminating improving the total defected parts. performance. 4. Responsibility of quality 4. Company wide, everybody control managers. is responsible. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 21
  22. 22. BENEFITS OF KAIZEN1. Savings in energy, material & others resources.2. Improvements in working environment.3. Improvements in machines & process.4. Improvements in jigs & tools.5. Capable of generating new ideas.6. Customer satisfaction.7. Elimination of wastes.8. Improvement in product quality.9. Improvement in 5S.10.Improvement in self personality.11.Improvements in own work.. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 22
  23. 23. HOW TO IMPLEMENT KAIZEN Employee identifies problem, waste or an opportunity for improvement and write it down The employee develops an improvement idea & discuss with his or her supervisor KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 23
  24. 24. The supervisor reviews the idea within 24hrs & encourages immediate action. The employee implements the idea The idea is written upon a simple Kaizen sheetKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 24
  25. 25. Supervisor publishes the Kaizen and rewards will be given CELEBRATE THE SUCCESS OF YOUR KAIZENKAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 25
  26. 26. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 26
  27. 27. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 27
  28. 28. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 28
  29. 29. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 29
  30. 30. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 30
  31. 31. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 31
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