1.
1
Created on February 2011
Kaizen for Lean manufacturing
Chap2 : Kaizen Collection of Cases
Created by Japanese Gemba Kaizen Web
http://takuminotie.com/english/

2.
2
Table of Content
1. Kaizen example: Boxing
2. Kaizen example: Airborne Dust
3. Kaizen example: Cup Noodles
4. Kaizen Example of Visualization ①
5. Kaizen Example of Visualization ②
6. Kaizen Example of Visualization ③
7. Kaizen Example of Visualization ④
8. Kaizen Example of Visualization ⑤
9. Kaizen Example of Visualization ⑥
10. Kaizen Example of Visualization ⑦

3.
3
1. Kaizen example: Boxing
Present condition
Boxing heavy products.
Issue: Arms are tired.
Traditional thinking:
1. Get used to it very soon at first.
2. Try your best spirit!
3. There is no enjoyable job!
Nothing perfects come into existence from the maintenance of the status quo.

4.
4
Issue: The arms are in pain.
Arms are in in pain? Why?
1. No strength. - Suggestion: Muscle-building
2. Heavy products. - Suggestion: Make them light.
3. Lifting - Suggestion: Make them do not need to be lifted.
Make them do not need to be lifted.
1. Aiming of entering it on the top of the box.
2. Aiming of exceeding the height of the box.
Why?
Why?
Why?
1. Kaizen example: Boxing
Of not in pain.
Load

5.
5
1. Slide into the box horizontally. 2. Drop from the top.
Topic: Hard to do.
Topic: Worry for the impact of falling.
The approach of Kaizen is to find the optimal way in the innumerable constraints.
1. Kaizen example: Boxing
Kaizen approach 1

6.
6
1. Side slope into the box. 2. Lay a cushion on the bottom of the box.
Topic: The cushions
cost.
It does not cost if it can be
responded immediately.
Cushion
Find the most suitable one out of the constraints!
1. Kaizen example: Boxing
Kaizen approach 2

7.
7
Change the work order.
Assemble the boxes, after that do not place the goods
into the box but assembles the products when the box is
plane.
1. Kaizen example: Boxing
Kaizen approach 3
It is better to assemble the products than not taken the empty space
reasonably before keeping the boxes planed as it is.

8.
8
2. Kaizen example: Airborne Dust
Rationalize the work and settlement to avoid airborne
dust caused by machining work.
Consider the steps of operating before implementing the operation.

9.
9
Damaged
noodles
3. Kaizen example: Cup Noodles
Issue: Frequent damage of the noodles in the process of inserting
noodles into the cups.
Remove the broken pieces of the noodles during the process of putting the noodles into the cup.

10.
10
4. Kaizen Example of Visualization ①
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Forget to turn the air-conditioner off. Attach the ribbon to the air outlet.
Cannot confirm with the eyes. Can confirm with the eyes.

11.
11
5. Kaizen Example of Visualization ②
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Forget to close the tap occurs. Change it to lever.
CloseOpen
Close
Open

12.
12
6. Kaizen Example of Visualization ③
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Forget ordering occurs. Turn the order form over once
an order has made.
Order form Order

13.
13
7. Kaizen Example of Visualization ④
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
The coffee has not served yet in an
order of a set of lunch and a cup of
coffee.
Prepare the spoon and plate
beforehand for the set served with
the coffee.
Order form 注文票

14.
14
8. Kaizen Example of Visualization ⑤
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Cannot manage the stationary of the
tools.
Implementation of the management
board.

15.
15
9. Kaizen Example of Visualization ⑥
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Does not know the screw is
loose.
Tightening of the loose screw
can be seen by eyes.

16.
16
10. Kaizen Example of Visualization ⑦
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen
Does not know where had one
return the book.
Immediately return to the book’s
original position because there is a
mark on it.

17.
17
Thank you for watching the show.
Please read the next chapter at My Home Page
and I hope Like us on Facebook
Regards.
Here my personal site→Japanese Geｍba Kaizen Web
my firm site →crane techno consultantｉｎｇ