Introduction to Kaizen & Lean Management
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Collaborated with my best friend on creating a very high-level introduction to Kaizen & Lean Management for her father's company in Bangladesh
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Introduction to Kaizen & Lean Management
- 2. INTRODUCING K AIZEN PHILOSPHY & LEAN MANAGEMENT C O N T I N U O U S I M P R O V E M E N T C U L T U R E F O R E V E R Y O N E , E V E R Y D AY, E V E R Y W H E R E . L U C K Y M O N Y
- 3. W H AT YO U W I L L TA KE AWAY W I T H YO U BY T H E E N D O F T H IS L E SSO N • Understanding of KAIZEN philosophy and Lean Management • Day to day application of KAIZEN and Lean Management (K&LM) • Importance and Benefits of K&LM • Adopt and apply basic KAIZEN concepts in your professional and personal life Presenter’s Note: The objective of this course is to introduce its learners to the basic concept and understanding of Kaizen philosophy and its application through various tools in Lean Management . The course is intended to invoke a cultural change and in time drive productivity in the minds and daily lives of those who are here today.
- 4. MEANING OF KAIZEN KAI •“Kai” in Japanese means : Change Evolve Transformation ZEN •“Zen” in Japanese means: Meditation – hereon applicable as “Awareness” Zen philosophy revolves around the importance of creating “Awareness of Life being at its best when simple” KAIZEN •When used together “KAI” & “ZEN” becomes KAIZEN which can be interpreted as: Self enhancement to universal balance Change for simplicity Removing unnecessary attributes in all aspects of life
- 5. KAIZEN CATEGORIES Restorative – improvement done to existing machine, man or process to its original state to fulfill objective Renovative - improvement done to existing machine, man or process to its enhanced state to fulfill objective Reimaginative - improvement done to machine, man or process to fulfill objective through replacement renewal
- 6. APPLICATION OF KAIZEN (H)enry & his 4 (W)ives WHO YOU! – You means, You the Manager, You the employee and You the husband and You the wife WHY Set-up a continuous improvement culture of effectiveness and efficiency WHERE Personal and Professional aspects of life WHEN At any time and if fact every time HOW – Various methods such as: Six Sigma, Lean Management and other methods when and where suitable
- 7. KAIZEN CASE STUDY Professional Personal
- 8. KAIZEN’S 3 ENEMIES – THE 3MS WASTEFUL MUDA IMBALANCE MURA OVERLOAD MURI HAVING LEARNT THE TYPES OF WASTES – LET’s MOVE ON TO CRITERIAS TO CONSIDER, WHEN IMPLEMENTING KAIZEN
- 9. KAIZEN - CRITERIAS FOR CONSIDERATION People&Management • Ineffective meetings • Lack of training • Unrecognized & Underutilized talent • Unclear job description • Unnecessary bureaucracy • Workplace politics • Non-compliance of Process&Policies • Non-documented process (Standard Operating Procedures) • Misinformation & Incorrect Information • Unorganized process (SOP) • No record of Information&Technology • Non governed inventory management • Over-allocated resources • Inefficient supply chain and logistics • Breakdown in machinery and transportation Materials&Environment • Unclean & Untidy workplace • Unsafe & Hazardous working condition • Wastage caused from left –over raw materials • Over stocking of assets which
- 10. K AIZEN PHILOSPHY DEMANDS THAT YOU TAKE A 15 MINS BREAK Y O U M AY N O W G O T O T H E R E S T R O O M S A N D R E M O V E A L L Y O U R W A S T E
- 11. BENEFITS OF LEAN MANAGEMENT
- 12. ACTIVITY: BRAINSTORM KAIZEN WITHIN ADEX’S DEPARTMENTS HR FINANCE S&M ADMIN PRODU CTION
- 13. IDENTIFIED MU-DA/RI/RA IN ADEX 1st ISSUE 2nd ISSUE 3rd ISSUE OWNER OWNER OWNER
- 14. QUESTION & ANSWER? T H A N K Y O U – L U C K Y M O N Y @ A D E X B D. C O M
Editor's Notes
- WIIFIM – what is it in for me?
- COST SAVINGS $ REVENUEGENERATION $$$ SELF FULFILLMENT ∞
- Facilitator notes: 0-5 mins: (5 mins) Divide team into 5 groups with each having a minimum of 3 members or manage in such a way that there are always odd number of teams Each team should be a mixed group consisting member from other departments – key is to allocate them under a department they work in proxy with (not so close) Hand them out post-it notes and ask them all to write within 5 minutes all the wastes that they think is being caused by their designated department 5-15 mins (10 mins) Once time is up, select or ask for volunteer from each team to collect all their post it notes and come up to you or a large board and organize them under their respective pillars Should there be a repeated idea of same nature – tell them to stack those up and draw out the count of it (example – waste of paper in HR came up x3 times) Once all laid on the board, thank them and ask them to return to their sits and tag another member from their teams to come up 15-25mins (10 mins) Ask these group read it all out and after which get them to call out similarities within departments – example HR waste of paper x3 as before but Finance and admin also have the same. Conclude and agree on finding a solution and ask them to use KAIZEN criteria when proposing the solution. 25-30mins (5mins) 1. Take your notes on this and identify active team members and non-active team members – depending on situation always give non-departmental manager to lead the project concerning the department(s) where the defect is. ===================== Production – productivity, cost, delivery, research and development quality, defects Human resource – pernosal growth, talent management, building strong workforce, training. Administration- cleanliness, law and order, Finance – supply chain management including inventory, transporation, over production, profit. Sales and marketing- after sales service, business planning, project completion, sales completion.