Conducting a kaizen
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This Presentation is about Kaizen and the results of Kaizen after conducting in a team
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Conducting a kaizen
- 1. 1 Kaizen
- 2. 2 1. Customer Needs 2. Design (Plan) 3. Do 4. Feedback (Check) 5. Improve (Act) What is Kaizen? Kaizen is continuous improvement that is based on certain guiding principles: •Good processes bring good results •Go see for yourself to grasp the current situation •Speak with data, manage by facts •Take action to contain and correct root causes of problems •Work as a team •Kaizen is everybody’s business
- 4. 4 Planning and Preparation There are 5 basic steps: • Identify the business case. • Set goals. • Select the team. • Collect baseline data. • Plan to support the Kaizen activity.
- 5. 5 Kaizen helps us to resolve the discrepancy between our customer's expectations and our current processes. The business case creates the focus for the kaizen and is documented on an A3. Examples of a business case for a kaizen include: • Reduce lead times • Increase delivery performance • Eliminate scrap • Reduce inventories • Increase capacity • Eliminate bottlenecks • Reduce changeover time • Reduce machine failures • Quality improvements Customer Eliminate the Gap!Eliminate the Gap! Identify the Business Case
- 6. 6 Set Goals •Measurable •Examples: Time, Money, Defects •Align with the company’s strategic goals and identified by the Plant A3 and Value Stream Map •Safety, Quality, Delivery, Cost •Stretch but realistic (target at least 50% improvement) •Should result in a new process or new standard •Documented on the an A3 •1 improvement idea per team member, PER OBSERVATION (6-7 ideas per person total)
- 7. 7 The Standard Work elements of a KaizenThe Standard Work elements of a Kaizen are:are: Document Reality Plan Countermeasures Identify Waste Reality Check Make Changes Verify Change Measure Results Make this the Standard Celebrate Do It Again Results: A new way of workA new way of work Start Stages of the Kaizen
- 8. 8 Problems Identified • Communication Problems • Unnecessary Movements • Internal Messenger • Record of Issues • Intellectual contribution • Rework • Equal Chance Obtainment • Knowledge of Previously made decisions to New Member
- 9. 9 Problems Suggested Solutions Communication Problems Once discussion is done, understanding of the same can be sent out as mail. This will act as a proof also when there is an issue. Unnecessary Movements We can request IT for an internal messenger Record of Issues Mail / Screenshots Rework Quality check can be done by themselves or internally in the team. Equal Chance Obtainment Sample Tasks can be given when an executive is free to check their skills. Knowledge of Previously made decisions to New Member We can note down those important decisions in a file and can be shared with New Joinees.
- 10. 10
Editor's Notes
- In order to meet our customer’s needs defined as internal and external, shareholders, employees, and our communities, we must design work (Plan), do the work (do), receive feedback to ensure the desired outcome is achieved (Check), and in our quest for the ideal we improve using feedback (Act). This is the PDCA cycle that Dr Deming spoke of in the 1950’s. Kaizen is one of the methods we use to achieve continuous improvement in a short period of time and is a tool for Rule 4 of the Rules-In-Use.
- Uses for Kaizen are important So is feeding the individual – make employment desirable/valuable Identify & Reduce Waste Reduce Costs Minimal/No Expense Employee Involvement Align actions to customer needs
- Cultural Change – permanent process evaluation/improvement change