1. The employees have taken an oath to continuously improve processes through Kaizen. 2. Visual management tools like color coding, labeling, and signal lights are used to clearly identify tools, materials, and workflow. 3. Standard work processes and 5S practices like cleaning and organizing the workplace have been implemented on the factory floor.

1. All the employees are involved in taking Kaizen Shapath

2. Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Employees

3. Director to Doorman - all are equally involved in doing Kaizen at GEMBA

4. Preventive Maintenance through Visual Management

5. Transparent
containers
Visual Management – Pigments stored in all the containers are visible and known

6. Through color coding, it is easy to know which tools and components belong to which dept.

7. Token
PEEP (Place For Everything and Everything in its Place)
When the person has taken a tool, he will place a token at the place that will let others
know where the tool is now and with whom

8. Color
coding
Standard
WIP
Output
Input
1. Frontline workers are cleaning their workstations to keep their workplace dust-free
2. Standard WIP has been kept near every workstation
3. All the components have been color coded according to their functionality and
stored at the point of use (POU)

9. Light indicator
to give signal
Plan vs. Actual
production
display board Material at
hands
distance
Packaging
This is an example of One Piece Flow Assembly
Each and every component needed is available at a hands distance of the worker

10. Worn out/Waste
tools are kept in
one line
Learning Center - where all kinds of tools are kept to train the employees

11. SMED
trolley
All the tools required (related to the machine) to perform the changeover are available in
SMED trolley. Big stand is available in the left corner where all the tools are kept that will
be needed during changeover, it helps to avoid Muda of Motion & Transportation

12. Responsibility has
been assigned to
Shift Fitter
SMED trolley contains all the tools required to perform quick changeover. SMED trolley
has been parked only in the right area

13. • Place for everything and every useful thing in its place (PEEP)
• Kanban system
• No stock out or over-stocking of material

14. Kanban
Collection
tray
Once any material has been picked up for use, the Kanban card of the particular material
will go into the Kanban collection tray. It will then be sent to purchase department at
every 11 am & 4 pm daily for placing the replenishment orders

15. Light
signal
Mizusumashi
(Water Spider)
Whenever the operators need some material, they trigger the light that gives signal to
Mizusumashi (Water Spider) who replenishes the required material in the workstation

16. Responsibility
assigned
Kanban
Card
Kanban
Board
Point of Use Storage (POUS) with Kanban

17. Name of the
Oil stored
Count
Free
Same color
marking is
done on
M/C
No Oil Drops
on the Floor
Visual Management

18. Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer

19. Kaizen For kids (KFK)

20. Yogesh Vaghani discussing the importance of Kaizen with School Faculty