3. Continuous
Improvement
Is the continuous
elimination of waste
4. KAI + ZEN
To modify, to change make good or
make better
= KAIZEN
“Making a change for the better”.
5. Kaizen was created in Japan following World War II.
The word Kaizen means " continuous improvement". It
comes from the Japanese words 改 ("kai") which
means "change" or "to correct" and 善 ("zen") which
means "good".
Kaizen is a system that involves every employee - from
upper management to the cleaning crew. Everyone is
encouraged to come up with small improvement
suggestions on a regular basis. This is not a once a
month or once a year activity. It is continuous.
Japanese companies, such as Toyota and Canon, a
total of 60 to 70 suggestions per employee per year
are written down, shared and implemented.
6. In most cases these are not ideas for major changes .
Kaizen is based on making little changes on a regular
basis: always improving productivity, safety and
effectiveness while reducing waste.
Suggestions are not limited to a specific area such as
production or marketing. Kaizen is based on making
changes anywhere that improvements can be made.
Western philosophy may be summarized as, " if it ain't
broke, don't fix it." The Kaizen philosophy is to " do it
better, make it better, improve it even if it isn't
broken, because if we don't, we can't compete with
those who do."
8. Visual Control & the Workstation
To Sort To Straighten
Ensure space for
Eliminate each thing, and a
what’s not thing for each
absolutely space. No more
necessary searching.
The To Sustain
5S Maintain
continuous
effort. This is a
way of life. To Sweep
To Sanitize Maintain a clean
and orderly space
Improvement to make problems
of the easily identifiable.
workstation. Eliminate rejects
Be organized and scrap..
to reduce
clutter.
9. Visual Control & the Workstation
Ergonomics
•Adapt the workstation to the
employee
- more security
- more comfort
•Reduce waste
- excessive fatigue
- useless efforts and
movement
- less physical constraints
10. THESE STEPS ARE SHORTEN INTO :
A.) Select an Event
B.) Plan an Event
C.) Implement an Event
D.) Follow-up to an Event
11. BENEFITS OF KAIZAN
Kaizen Reduces Waste- like
inventory waste, time waste,
workers motion
Kaizen Improves space
utilization, product quality
Results in higher employee
moral and job satisfaction,
and lower turn-over.
Toyota is well-known as one of the
leaders in using Kaizen. In 1999 at
one U.S. plant, 7,000 Toyota
employees submitted over 75,000
suggestions, of which 99% were
implemented.
12. PIT FALLS IN KAIZEN
Resistance to
change
Lack of proper
procedure to
implement
Too much
suggestion may
lead to confusion
and time wastage
Editor's Notes
These are the seven characteristic types of waste affecting process performance. Everything we do or make that does not add value to the product is waste. The goal is to minimize wastes, maximize value add.
All conditions existing in the workplace that act to complicate or impede efficiency in meeting desired product or service requirements are the focus of improvement. This includes housekeeping, the 5 steps of which are diagrammed above.
Equally important to productive efficiency is attention to the ergonomics conditions of the workstation. Excessive or difficult movements in accomplishing tasks create muda, and should be addressed.
