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WELCOME
Engr. Abdun Noor
bd.abdunnoor@gmail.com
Associate Consultant
Centre for Management Development
SEL Centre (6th Floor), 29-West Panthapath, Dhaka-1205, Bangladesh
cmdconsultant@yahoo.com
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
TRAINING ON:TRAINING ON:
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
What is KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
What is KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
What is KAIZEN?
 SSmall andmall and un-dramatic improvement and its resultsun-dramatic improvement and its results
are seldom immediately visibleare seldom immediately visible, but it is continuous, but it is continuous
thus brings good resultsthus brings good results
 KAIZEN employs simple ideas and common senseKAIZEN employs simple ideas and common sense
 KAIZEN is based on the simple principle that we
need continuous improvement in order to progress
and advance
 The KAIZEN strategy is that ‘not a single day
should go by without some kind of improvement’.
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN is:
 Making small improvements with little costMaking small improvements with little cost
 Making small improvements all the time - alwaysMaking small improvements all the time - always
thinking of doing something better today thanthinking of doing something better today than
yesterdayyesterday
 Allowing everyone to make improvements
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
What is KAIZEN?
KAIZEN inspire toKAIZEN inspire to
 Think outside the boxThink outside the box
 Think in a different wayThink in a different way
 Bring out CreativityBring out Creativity
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
How Improvement is Made?
 Innovation/ ModernizationInnovation/ Modernization
&&
 KAIZENKAIZEN
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN and Innovation/ Modernization :
 KAIZEN signifies small improvements made inKAIZEN signifies small improvements made in
the status quo as a result of ongoing effortsthe status quo as a result of ongoing efforts
 Innovation/Modernization involves a drastic
improvement in the status quo as a result of a
large investment in new technology, product
and/or equipment
 While KAIZEN is a continuous process,
innovation is generally a one-shot phenomenon
 KAIZEN does not necessarily require
sophisticated technique or call for a large
investment to implement it.
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN and Innovation/ Modernization :
TIMETIME
TIMETIME
KAIZENKAIZEN
Innovation/ ModernizationInnovation/ Modernization
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Why KAIZEN?
 One of the famous Parkinson’s Laws is that “An
organization, once it has built its edifice, begins
its decline.”
 Therefore, there must be a continuing effort for
improvement to even maintain the status.
 Even when modernization / innovation makes a
radical improvement in standard of performance,
the new performance level will decline unless the
standards is constantly challenged and upgraded
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Why KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Why KAIZEN?
What should beWhat should be
(standard)(standard)
What actuallyWhat actually
isis
Innovation/Innovation/
ModernizationModernization
TimeTime
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN & Management
Innovation/
Modernization
KAIZEN
Maintenance
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Targets of KAIZEN
 KAIZEN targets for 3Ms for improvementKAIZEN targets for 3Ms for improvement
11stst
MM
MUDAMUDA
無駄無駄
WastageWastage
(Avoid all(Avoid all
wastage)wastage)
22ndnd
MM
MURIMURI
無理無理
StrainStrain
(Causing(Causing
in-efficiencyin-efficiency
avoid strain,avoid strain,
workwork
smarter)smarter)
33rdrd
MM
MURAMURA
斑斑
ErrorError
(Avoid errors/(Avoid errors/
Discrepancies,Discrepancies,
Think Poka-Think Poka-
Yoke)Yoke)
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN
 KAIZEN employs simple ideas and common
sense
 KAIZEN is more a mind-set than a technique
(Positive mind set)
 A mind-set that “there is always a better way of
doing something.”
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN Checklist (Sample)
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN Checklist (Sample)
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN Checklist (Sample)
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN Checklist (Sample)
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
KAIZEN Example:
Productivity Improvement of Packaging Material in a Biscuit CompanyProductivity Improvement of Packaging Material in a Biscuit Company
Sl
No
Name of materials and existing
dimensions
Existing cost
(Tk.)
Proposed
Dimension
Savings (Tk.)
1. Grease Paper (24 no)
25.3 × 16.6 cm
1.52 25.3 × 15.24 cm. 0.17
2. Coloured Cellophane (24 no)
19.3x16.5 cm
2.39 18.3 × 16.5 cm. 0.12
3. Polythene bag (1 no)
43×41cm
0.48 39.5 × 43 cm. 0.02
4. Batch coupon 1 no 0.01 Ok. - -
5. M.P.P. (Solid) Carton
21.7 × 21.1 × 12 cm.
2.79 Ok. - -
6. Gum tape 1½ cm. 0.09 Ok. - -
7. Gm Tape 0.08 Ok. - -
Tk. 7.36 per Carton Tk. 0.31 Per carton
Yearly production =Yearly production = 469885 Carton469885 Carton
Yearly SavingsYearly Savings == Tk. 0.31Tk. 0.31 ×× 46988 =46988 = Tk. 1, 45,664.35Tk. 1, 45,664.35
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Before KAIZEN?
A pool (Sheep dip) was used to remove insects from the sheep’sA pool (Sheep dip) was used to remove insects from the sheep’s
bodies. We had to push the heads of the sheep down to submergebodies. We had to push the heads of the sheep down to submerge
them into the water mixed with insecticide.them into the water mixed with insecticide.
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
After KAIZEN?
A pit was made at the bottom of the pool. This meant the sheepA pit was made at the bottom of the pool. This meant the sheep
would submerge their heads by themselveswould submerge their heads by themselves
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Before KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
After KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Before KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
After KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Before KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
After KAIZEN?
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
More KAIZEN examples?
Few examples from daily life?
 Bus supervisor example
 CNG driver example
 Coconut leaf-fan example
 V-belt example
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Examples of Poka-Yoke
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Examples of Poka-Yoke: KAIZEN
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Examples of Poka-Yoke: KAIZEN
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
Before KAIZEN:
There was a strain in mounting the
Bracket bellow support on to slim3
machine. 2 persons required to
assemble the cover
After KAIZEN:
Fixture made by using simple frame
from in-house parts. Single person can
assemble the cover. Easy handling of
part since crane will be used
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
Before KAIZEN:
The storage of spindle shafts was
being done with the help of a wooden
V block fixture. This method was
prone to damages
After KAIZEN:
Special trolley introduced for storage
of spindle shafts. Easy handling of
spindle shafts. No damages will be
caused during transport
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
Before KAIZEN:
CMM probe was kept on a surface
table. Due to this being a regular
working area there were chances of
probe getting damaged . The probe is
very expensive and costs
After KAIZEN:
Probe damage avoided completely.
House keeping also improved on
CMM surface table
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
Before KAIZEN:
There was no fixture for proximity
tightening
After KAIZEN:
Two holes made on the table so that
proximity can be fixed while
tightening the connectors
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN: Before
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN: After
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Lower the
table
Raise the
table
You can’t change the
Table height
Few examples of KAIZEN
Footstool
Easy to
work.
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com
Few examples of KAIZEN
KAIZEN Technique

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KAIZEN Technique

  • 1. WELCOME Engr. Abdun Noor bd.abdunnoor@gmail.com Associate Consultant Centre for Management Development SEL Centre (6th Floor), 29-West Panthapath, Dhaka-1205, Bangladesh cmdconsultant@yahoo.com
  • 2. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com TRAINING ON:TRAINING ON:
  • 3. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com What is KAIZEN?
  • 4. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com What is KAIZEN?
  • 5. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com What is KAIZEN?  SSmall andmall and un-dramatic improvement and its resultsun-dramatic improvement and its results are seldom immediately visibleare seldom immediately visible, but it is continuous, but it is continuous thus brings good resultsthus brings good results  KAIZEN employs simple ideas and common senseKAIZEN employs simple ideas and common sense  KAIZEN is based on the simple principle that we need continuous improvement in order to progress and advance  The KAIZEN strategy is that ‘not a single day should go by without some kind of improvement’.
  • 6. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN is:  Making small improvements with little costMaking small improvements with little cost  Making small improvements all the time - alwaysMaking small improvements all the time - always thinking of doing something better today thanthinking of doing something better today than yesterdayyesterday  Allowing everyone to make improvements
  • 7. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com What is KAIZEN? KAIZEN inspire toKAIZEN inspire to  Think outside the boxThink outside the box  Think in a different wayThink in a different way  Bring out CreativityBring out Creativity
  • 8. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com How Improvement is Made?  Innovation/ ModernizationInnovation/ Modernization &&  KAIZENKAIZEN
  • 9. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN and Innovation/ Modernization :  KAIZEN signifies small improvements made inKAIZEN signifies small improvements made in the status quo as a result of ongoing effortsthe status quo as a result of ongoing efforts  Innovation/Modernization involves a drastic improvement in the status quo as a result of a large investment in new technology, product and/or equipment  While KAIZEN is a continuous process, innovation is generally a one-shot phenomenon  KAIZEN does not necessarily require sophisticated technique or call for a large investment to implement it.
  • 10. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN and Innovation/ Modernization : TIMETIME TIMETIME KAIZENKAIZEN Innovation/ ModernizationInnovation/ Modernization
  • 11. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Why KAIZEN?  One of the famous Parkinson’s Laws is that “An organization, once it has built its edifice, begins its decline.”  Therefore, there must be a continuing effort for improvement to even maintain the status.  Even when modernization / innovation makes a radical improvement in standard of performance, the new performance level will decline unless the standards is constantly challenged and upgraded
  • 12. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Why KAIZEN?
  • 13. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Why KAIZEN? What should beWhat should be (standard)(standard) What actuallyWhat actually isis Innovation/Innovation/ ModernizationModernization TimeTime
  • 14. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN & Management Innovation/ Modernization KAIZEN Maintenance
  • 15. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Targets of KAIZEN  KAIZEN targets for 3Ms for improvementKAIZEN targets for 3Ms for improvement 11stst MM MUDAMUDA 無駄無駄 WastageWastage (Avoid all(Avoid all wastage)wastage) 22ndnd MM MURIMURI 無理無理 StrainStrain (Causing(Causing in-efficiencyin-efficiency avoid strain,avoid strain, workwork smarter)smarter) 33rdrd MM MURAMURA 斑斑 ErrorError (Avoid errors/(Avoid errors/ Discrepancies,Discrepancies, Think Poka-Think Poka- Yoke)Yoke)
  • 16. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN  KAIZEN employs simple ideas and common sense  KAIZEN is more a mind-set than a technique (Positive mind set)  A mind-set that “there is always a better way of doing something.”
  • 17. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN Checklist (Sample)
  • 18. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN Checklist (Sample)
  • 19. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN Checklist (Sample)
  • 20. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN Checklist (Sample)
  • 21. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN
  • 22. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com KAIZEN Example: Productivity Improvement of Packaging Material in a Biscuit CompanyProductivity Improvement of Packaging Material in a Biscuit Company Sl No Name of materials and existing dimensions Existing cost (Tk.) Proposed Dimension Savings (Tk.) 1. Grease Paper (24 no) 25.3 × 16.6 cm 1.52 25.3 × 15.24 cm. 0.17 2. Coloured Cellophane (24 no) 19.3x16.5 cm 2.39 18.3 × 16.5 cm. 0.12 3. Polythene bag (1 no) 43×41cm 0.48 39.5 × 43 cm. 0.02 4. Batch coupon 1 no 0.01 Ok. - - 5. M.P.P. (Solid) Carton 21.7 × 21.1 × 12 cm. 2.79 Ok. - - 6. Gum tape 1½ cm. 0.09 Ok. - - 7. Gm Tape 0.08 Ok. - - Tk. 7.36 per Carton Tk. 0.31 Per carton Yearly production =Yearly production = 469885 Carton469885 Carton Yearly SavingsYearly Savings == Tk. 0.31Tk. 0.31 ×× 46988 =46988 = Tk. 1, 45,664.35Tk. 1, 45,664.35
  • 23. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Before KAIZEN? A pool (Sheep dip) was used to remove insects from the sheep’sA pool (Sheep dip) was used to remove insects from the sheep’s bodies. We had to push the heads of the sheep down to submergebodies. We had to push the heads of the sheep down to submerge them into the water mixed with insecticide.them into the water mixed with insecticide.
  • 24. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com After KAIZEN? A pit was made at the bottom of the pool. This meant the sheepA pit was made at the bottom of the pool. This meant the sheep would submerge their heads by themselveswould submerge their heads by themselves
  • 25. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Before KAIZEN?
  • 26. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com After KAIZEN?
  • 27. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Before KAIZEN?
  • 28. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com After KAIZEN?
  • 29. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Before KAIZEN?
  • 30. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com After KAIZEN?
  • 31. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com More KAIZEN examples? Few examples from daily life?  Bus supervisor example  CNG driver example  Coconut leaf-fan example  V-belt example
  • 32. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Examples of Poka-Yoke
  • 33. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Examples of Poka-Yoke: KAIZEN
  • 34. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Examples of Poka-Yoke: KAIZEN
  • 35. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN Before KAIZEN: There was a strain in mounting the Bracket bellow support on to slim3 machine. 2 persons required to assemble the cover After KAIZEN: Fixture made by using simple frame from in-house parts. Single person can assemble the cover. Easy handling of part since crane will be used
  • 36. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN Before KAIZEN: The storage of spindle shafts was being done with the help of a wooden V block fixture. This method was prone to damages After KAIZEN: Special trolley introduced for storage of spindle shafts. Easy handling of spindle shafts. No damages will be caused during transport
  • 37. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN Before KAIZEN: CMM probe was kept on a surface table. Due to this being a regular working area there were chances of probe getting damaged . The probe is very expensive and costs After KAIZEN: Probe damage avoided completely. House keeping also improved on CMM surface table
  • 38. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN Before KAIZEN: There was no fixture for proximity tightening After KAIZEN: Two holes made on the table so that proximity can be fixed while tightening the connectors
  • 39. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN: Before
  • 40. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN: After
  • 41. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Lower the table Raise the table You can’t change the Table height Few examples of KAIZEN Footstool Easy to work.
  • 42. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN
  • 43. Engr. Abdun Noor, Centre for Management Development, bd.abdunnoor@gmail.com Few examples of KAIZEN