Kaizen is a Japanese term meaning continuous improvement. It originated from combining the Japanese words "Kai" meaning change and "Zen" meaning improvement. Kaizen focuses on continuously improving manufacturing, engineering, and business management processes by involving all employees. The PDCA (Plan-Do-Check-Act) model is used as the system for executing Kaizen in a four step approach. Some key advantages of Kaizen include reducing waste, improving employee utilization and production, and reducing completion cycle times.

1. KAIZEN
SYED MOHAMMAD HASSAN
NOUKHAIZ ASLAM
AWAIS AHMED
ABUZAR KHAN

2. WHAT IS KAIZEN?
 A Japanese term for improvement.
 Derived from two terms
 KAI meaning Change
 ZEN meaning Continuous Improvement
 Improvement in
 Manufacturing
 Engineering
 Business management
 First implemented in Japan.
 Involves all employees.

3. PDCA MODEL
 System for executing Kaizen.
 Four step management model.
 The acronym stands for
 Plan
 Do
 Check
 Act

4. KAIZEN'S ADVANTAGES
 Reduces waste
 Improves employee utilization
 Improves production
 Reduces completion cycle time
 Higher job satisfaction

5. PERSONS INVOLVED
 Praise and encourage participation.
 People at every level are involved.
 The key people involved are;
 The subject matter expert
 The process owner
 Front-line workers
 An outside novice

6. IMPLEMENTING KAIZEN
 A critical business issue is identified.
 A Project Leader is selected.
 Project Leader selects a team
 Train the event team
 Gather data and facts
 Report and implementation plan is created.
 Implementation on small scale.
 A Final Report is presented

7. TOYOTA PRODUCTION SYSTEM
 Kaizen resulted from the competition between Nissan
and Toyota.
 Nissan won 'Deming' prize in 1961.
 Toyota became more aggressive.
 Developed the Toyota Quality Circles in 1962.

8. TECHNIQUES USED IN TPS
 The Production Cell
 Just in Time (JIT)
 Total productive maintenance
 5s
 Single Piece Flow
 Quality Control Circle
 Waste

9. KAIZEN COSTING
 Kaizen costing techniques are used in TPS.
 Used to manage cost and standard time.
 Director of the Production Division is responsible.
 A Cost Council held every month.

10. KAIZEN PRODUCTION EFFICIENCY MANAGEMENT
 Toyota production line “Shôjinka”.
 Group leaders are in charge of reducing the cycle time.
 Increasing production efficiency.
 Lowering production cost.

11. KAIZEN MIND
 Workers are encouraged to suggest ideas.
 Thinking about workplace is important.
 Such voluntary activities increases efficiency.
 Helps to obtain the abilities required for becoming
supervisory.

12. KAIZEN FOR MAKING ASSEMBLY WORK
MORE ATTRACTIVE
 A new concept of assembly line developed.
 Assembly line was divided into about ten segments.
 A buffer between two segments.
 Group leader is allowed to stop the segment during the
buffer.
 A group can hold a meeting during buffer time.
 Each segment also has a quality checking post.

13. PIT FALLS IN KAIZEN
 Resistance to change.
 Lack of proper procedure to implement.
 Too much suggestion may lead to confusion and time
wastage.

14. RECOMMENDATIONS
 Employees consent and views must be taken into
account.
 Use of well defined procedures.
 Well defined procedures must be observed.

15. THANK YOU