This document outlines the key concepts and processes of Kaizen, a Japanese philosophy of continuous improvement. It discusses the differences between innovation and Kaizen, as well as Western and Japanese perceptions of products. It then provides details on implementing a Kaizen program, including forming teams, using tools like 5S and the 7 QC tools, conducting projects to reduce waste and improve processes/productivity, and assessing/rewarding results. The overall message is that Kaizen is about continuous growth through small improvements and teamwork.

1. Process Oriented vs. Result Oriented
Criteria

2. Features of Kaizen and Innovation

3. Ideal Pattern from Innovation

4. Actual Pattern From Innovation

5. Innovation alone

6. Innovation plus KAIZEN

7. Western and Japanese product
perception

8. Problem solving

9. The Five Ws and One H of KAIZEN

10. KAIZEN Suggestion System
 Fill up the form and register the KAIZEN
 Discuss with HOD of concerned Dept
 Assessment with GM and KAIZEN Coordinator
 Implementation by Owner

11. Great Sayings….
Nothing gives you More Satisfaction and Motivation than
when you see your IDEAS being adopted by the work
place. Just money can never keep a human being
motivated in the real sense.
-Taiichi Ohno.
Father of Toyota Production System

12. Training
 Problem solving process
 Use of 7 QC tools
 Use of ‘5 why’

13. Training………Contd
7 QC tools
1) Check sheets
2) Histogram
3) Pareto diagram
4) Control charts
5) Scatter diagram
6) Cause and effect diagram
7) Graphs

14. Training………Contd
3 - MU
MUDA - Waste
MURA - Inconsistency
MURI - Inconvenience

15. Training………Contd
5S
SEIRI - Sort
SEITON - Straighten
SEISO - Shine
SEIKETSU - Standardize
SHITSUKE - Sustain

16. Training………Contd
3G
GEMBA - Actual Place
GEMBUTSU - Actual Thing
GENJITSU - Act

17. Working
KAIZEN Projects
1) Reduction in mechanical breakdown
2) Reduction in electrical breakdown
3) On-line process
4) Reduction in consumables
5) Identification / utilization of excess manpower
6) Zero Leakage
7) Waste control and its application
8) Productivity improvement
9) Maintenance improvement
10) House keeping,
AND MANY MORE …….

18. Working …………Contd
Project Methodology
 Support to each department
 Voluntary participation
 8/10 member in each team
 Team leader elected by group
 Monthly presentation
 Final assessment

19. Working…………Contd
Assessment
 Overall best KAIZEN
 Best KAIZEN in creativity / safety / productivity / housekeeping
/ cost reduction
 Most implemented KAIZENS
 At each 10 / 25 / 50 implemented KAIZENS
 Best Project / Theme Group
 Best Creative Employee
 Best KAIZEN Employee involvement and initiative
 Best KAIZEN by workers top 3
 Best Facilitator
 Surprise awards
 Best Department

20. Working …………Contd
We don’t see KAIZEN as management tool
BUT
a ladder for
‘CONTINUOUS GROWTH THRU’ SMALL
IMPROVEMENTS’.

21. Guru Mantra of Kaizen
The difference between
knowing something and success lies in
Doing !!
Remember
KAIZEN
is all about
TEAM WORK !!

22. THANK YOU
Vijay Prakash Pandey
Chief Human Resource Officer
C L Gupta Exports Limited