The ultimate solution of industrial problems KAIZEN

1. KM 1
KAIZEN Management
Characteristics of
Japanese Production
Systems
By. S.M. JUNAID

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

3. KM 3
Q, C, D
What are evaluation
criteria for the output ?
Q: Quality
C: Cost
D: Delivery
Industry
Input Output
KAIZEN
action

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

5. KM 5
KAIZEN is a Japanese
word.

6. KM 6
Definition of KAIZEN

7. KM 7
1. A selection of better means
or a change of current
method for achieving an
objective.
Definitions of KAIZEN
2. An accumulation of small
changes

8. KM 8
The way of packing orangesThe way of packing oranges
in Japanin Japan

9. KM 9
It is difficult to open a net and put
oranges in the net at the same time.
Productivity: 1 net per min.
Orange Packing (1)
I need
help.

10. KM 10
Cooperation increases a work efficiency.
Productivity: 5 nets per min.
Orange Packing
(2)
with 2 workers

11. KM 11
Can you think of a better
method to pack oranges?
Productivity: 5 nets per min. with 1 worker

12. KM 12CLIP

13. KM 13
KAIZEN is a
continuous improvement
Continuous = again and again, ongoing

14. KM 14
- I picked up a garbage and
put it in a trashcan.
- I wiped the windows and
made them clean.
- I used a mop to clean the gasoline
left on the floor.
KAIZEN is a small change to
make something better.
Where is a division between
our jobs and KAIZEN?

15. KM 15
A small change of a method
- KAIZEN is to change a way of using
the mop
Any way to pick up the mop?
Any way to store the mop?
Any way to carry the mop?
KAIZEN is a small change

16. KM 16
Improvement by
changing methods
How do we change methods?

17. KM 17
KAIZEN Steps

18. KM 18
- Abolition
- Discontinuance
- Exclusion
- Removal
- Simplification
- Centralization
- Synchronization
- Standardization
- Management for exceptions
- Integration
- Combination
- Alternation
- Exchange
- Conversion
- Diversification
- Separation
KAIZEN Steps

19. KM 19
- Abolition
- Discontinuance
- Exclusion
- Removal
- Simplification
- Centralization
- Synchronization
- Standardization
- Management for exceptions
- Integration
- Combination
- Alternation
- Exchange
- Conversion
- Diversification
- Separation
KAIZEN Steps Review

20. KM 20
Elimination Remove this
sliding door
What is the use of the sliding
doors?

21. KM 21
KAIZEN by “Elimination”
Before After
Why are shoe box doors needed?

22. KM 22
Before
After
KAIZEN by “Elimination”
No sleeves down-jacket is easy to
work.

23. KM 23
The number of fluorescent lights
was reduced.
Reduce A fluorescent light
bulb was removed.

24. KM 24
KAIZEN by “Reduction”
Before
Are two bricks needed
to stop a car?

25. KM 25
Parking Lot

26. KM 26
After
Before
KAIZEN by “Reduction”
One brick is enough
to stop a car.

27. KM 27CLIP

28. KM 28
Zebra Zone
1

29. KM 29
Before
After
KAIZEN by “Reduction”
Side lines of
the zebra zone
are removed.

30. KM 30
Before After
KAIZEN by “Reduction”
A brush part of the toothbrush is
not necessarily long.

31. KM 31
toothbrushes

32. KM 32
By watching the ribbon movement,
one can recognize that the air
conditioner is working.
Change

33. KM 33
KAIZEN by “Change”
Before After
The hollow about the key hole
smoothes the key movement.

34. KM 34
Before After
KAIZEN by “Change”
To oil the pan, a small teapot is
more convenient than a ladle.

35. KM 35
Before After
KAIZEN by “Change”
Stairways at the railway station
should have signs of up and
down.

36. KM 36
At JR Kurume StationAt JR Kurume Station

37. KM 37
Before After
KAIZEN by “Change”
The shape of the hanging strap
fits the hand.

38. KM 38
Hanging Straps
in JR trains

39. KM 39
Hanging strap inHanging strap in
Hong Kong subwaysHong Kong subways

40. KM 40
Suggestion System
vs.
KAIZEN Suggestion System

41. KM 41
Suggestion System
You suggest your ideas, and I will
examine them and implement some
of your ideas later.

42. KM 42
Suggestion System Concept
Reward
Idea
Idea

43. KM 43
KAIZEN Suggestion System
KAIZEN
sheet
Implemented KAIZEN ideas must
be submitted

44. KM 44
Workers’
responsibility
Workers’ responsibility
Management responsibility
Management
responsibility
Suggestion System
KAIZEN Suggestion System
Difference (1)

45. KM 45
Suggestion System
Propose improvement ideas for any
activity in the company.
KAIZEN Suggestion System
Propose only improvement ideas
which will improve your own work.
Difference (2)

46. KM 46
1. Small change
2. Medium change
3. Big change
(KAIZEN)
(Small group
activities)
(Innovation)
--- By individual effort, a better
way of proceeding a job is
considered. (Idea creation)
--- By group effort, a better way
is proposed by following
predetermined steps (or
rule).
--- By investments in new technology
or equipment, dramatic alterations
are achieved.
Different styles of change

47. KM 47
Appreciation
Identify & Initiative
Management
Staff
Floor people
Two Attitudes

48. KM 48
K
A
IZEN
Initiative
Appreciation
K
A
IZEN
Initiative
Management
Staff
Floor people
Management
Staff
Floor people
Appreciation
Japanese firms
Non-Japanese firms
Two Attitudes