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Gemba Kaizen for lean manufacturing chap2 | kaizen collection of cases | lean tools

Introduce Japanese Kaizen lean manufacturing
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Table of Content

Kaizen example: Boxing
Kaizen example: Airborne Dust
Kaizen example: Cup Noodles
Kaizen Example of Visualization ①
Kaizen Example of Visualization ②
Kaizen Example of Visualization ③
Kaizen Example of Visualization ④
Kaizen Example of Visualization ⑤
Kaizen Example of Visualization ⑥
Kaizen Example of Visualization ⑦

Gemba Kaizen for lean manufacturing chap2 | kaizen collection of cases | lean tools

  1. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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

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