Kaizen definition
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This document presents an overview of the Kaizen philosophy. It discusses the key principles of Kaizen including making small incremental changes to improve productivity and minimize waste. The literature review covers the main elements of Kaizen such as teamwork, personal discipline, and suggestion for improvement. It also examines the three M's in Kaizen - Muda, Muri, and Mura. The document outlines the steps in the Kaizen process walk and highlights advantages like reducing waste and improving quality, as well as potential disadvantages like resistance to change.
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Kaizen definition
- 1. KAIZEN PHILOSOPHY Presented to In partial Fulfillment Of the Requirement for the Degree Master of Science Engineering Technology Management By Aida Pourshirazi Spring2017 1
- 3. Introduction Masaaki Imai Kaizen pioneer What is Kaizen ? 3
- 4. • This Is Small incremental changes made for improving productivity and minimizing waste Introduction Definition of Kaizen 4
- 5. • 3 main principles of Kaizen • Consider the process and the result . • The need to look at the entire process of the job at the hand and evaluate job as the best way to get the job done . • Kaizen must approached in such a way that no one is blamed and that best process is put into place. Literature Review 5
- 6. Team Work Personal discipline Improved Moral Quality Suggestion for improvement Kaizen Key Elements Literature Review 6
- 7. • Widely applicable • Highly effective and result oriented • A learning experience • Team based and cross- functional Literature Review Features Of Kaizen 7
- 8. Literature Review • Muda • Any wasteful activity or and destruction of the smooth for of an activity • Muri • Physical Strain • Rushed to work • Mura • Inconsistence in the system What are 3 M in Kaizen ? 8
- 10. 5s of Kaizen Literature Review 10
- 11. Literature Review Kaizen and Standardization 11
- 12. Kaizen and Innovation Literature Review 12
- 13. Implementation of Kaizen Literature Review 13
- 14. 1.Discover improvement potential 2.Analyzing the current method 3.Generate the Original Ideas 4.Develop an implementation plan 5. Implement the plan 6.Eveluate the new method Steps of the process walk 14 Literature Review
- 15. • Kaizen reduce waste-like inventory waste, Time waste, and worker motion . • Kaizen improves space utilization and product quality . • Result in higher employee moral and job satisfaction . • Teaches workers how to solve everyday problem. Literature Review Advantages of Kaizen 15
- 16. • Resistance to change. • Too much suggestion may lead to confusion and time wastage. • Difficult to implement in large scale process, where analyzing spends lots of time. Disadvantages of Kaizen Literature Review 16
- 17. Case study 17
- 18. Conclusion • Kaizen helps you to ….. • See the Waste !!!!! • Turn problem into the profit !!!!! • Constantly change for better!!!!! 18
- 19. Any question? 19
- 20. • Berger, A. (1997). Continuous improvement and Kaizen: standardization and organizational designs. Integrated manufacturing systems, 8(2), 110-117. • Bessant, J., Caffyn, S., Gilbert, J., Harding, R., & Webb, S. (1994). Rediscovering continuous improvement. Tec novation, 14(1), 17-29 • Cheser, R. (1994). Kaizen is more than continuous improvement. Quality Progress, 27(4),23-26. • Dhongade, P. M., Singh, M., & Shrouty, V. A. (2013). A Review: Literature Survey for the Implementation of Kaizen. International Journal of Engineering and Innovative Technology (IJEIT) Volume, 3, 57-60. • • Kumar; P., & Pandey, V. (2103). KAIZEN: A Case study in small scale organizations. International Journal of Scientific Research Engineering & Technology (IJSRET), 2(2), 133-136. Retrieved from www.ijsret.org. • Liker, J. K. (1997). Becoming lean: Inside stories of US manufacturers. CRC Press. • Masaaki, I. (1986). Kaizen: The key to Japan's competitive success. New York, ltd: McGraw-Hill. • Paul Brunet, A., & New, S. (2003). Kaizen in Japan: an empirical study. International Journal of Operations & Production Management, 23(12), 1426-1446. • Schoeder, D. M., & Robinson, A. G. (1991). America's most successful export to Japan: Continuous improvement programs. Quality control and applied statistics,36(11), 655. • Suarez Barraza, M. F., Smith, T., & Mi Dahlgaard-Park, S. (2009). Lean-kaizen public service: an empirical approach in Spanish local governments. The TQM Journal, 21(2), 143-167. • References 20
Editor's Notes
- It is word of founder : Kaizen is an improvement or ongoing improvement consisting every one from top management , managers to workers. the concept of Kaizen became popular in the United States only by the late 1980’s.
- While increasing the profit
- Kaizen is all about removing 3ms Muri put souch stress Mura unevenes
- Demings cycle All standards usually set by upper management in the company, however, they should be able to make changes in standards whenever the environment changes. Organizations can accomplish significant improvement if management review standards frequently aBy doing frequents check on the process, management can be able to encourage their teams to solve the problem in the process (Liker, 1997). When standards are in place and being followed up then if there were in deviation, employees would realize that there is a defect in the process. Thus, they can revise standards to correct deviation or recommend to management to change and improve the standard. This is an ongoing process that it is presented by Dr.Demming which is known as the Kaizen PDCA cycle (plan-do-check-act) or Demming cycle in the Figure7.
- KKaizen basically, supports the improvement in the exciting activities (Cheser, 1994). However, it will not provide the significant step forward. Consequently, it is critical for firms to sustain a balance between innovation and kaizen strategy to have continuous improvement in their process. Keeping this balance is mainly, top management’s duty. They are in charge to look for any possible innovative opportunities as much as possible. Kaizen methodology implies small improvement made in the current situation by continuous efforts (Paul Brunet, & New, 2003). Whereas, innovation usually brings a drastic enhancement in the present situation by investing in the new technology as well as equipment or even re-engineering the whole process if it is necessary. Following table shows some differences between kaizen and innovation (Paul Brunet, & New, 2003).
- Discover improvement
- 2 which will bring customer statisfaction
- Kaizen case study was applied in a small-scale organization in the wire harness manufacturing industry for automotive vehicles (Kumar, & Pandey, 2103). The case study focused on cost reduction by doing modification in the process as well as made an improvement to achieve minimum rejection level in products (Kumar, & Pandey, 2103). The process that applied for cost reduction was as following: The problem was excessive cycle time as well as poor quality which was frequently happening in the resistor leg bending in the assembly, tube, cutting and slitting. The action for this problem was providing the jig for the leg because the reason was the problem was leg bending with the nose pillar as it can be seen in the picture the leg bending before improvement and the figure 10 leg bending after improvement. The result was the implementation of these kaizen activities we can save 50-60% time and cost reduction. The Tangible and Intangible benefits were (a.) Reduction in Manpower. (b.) Cost Reduction. (c.) Productivity improvement (d.) Over time reduction.
- Conclusion Kaizen is the method that is essential for the companies that applied lean into their process. Kaizen or continuous improvement is the constant improvement in the process from start to end. The key elements of kaizen are teamwork, personal discipline, improved morale and quality circle. There also 5s which are required to be implemented in the organization to achieve Kaizen successfully. Kaizen is not just a method is also a culture of continuous improvement in the companies. Thus, companies that could apply kaizen correctly can have a benefit of customer satisfaction about their product while having the minimum waste in the process. Kaizen is one of the most important concepts in the lean methodology.