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201156627-Kaizen-Lesson-Power-Point-Presentation.ppt
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- 2. Aim • The aimof this presentation is to introduce the Kaizen Philosophy, its principles and benefits.
- 3. Objective • At theend of the presentation the audience should be able to apply the Kaizen principle correctly for a continuous improved performance in the execution of their assigned tasks.
- 4. Scope • Kaizen philosophy •Basic concept of Kaizen • Kaizen Approach • Steps in Kaizen • Principles of Kaizen • Theme of Kaizen • Kaizen tools • The 5 elements • Benefits of Kaizen • PDCA cycle
- 5. Introduction • “KAIZEN” isan activity to improve productivity by recognizing the existing situation and solving the problems of the organization continuously and gradually utilizing existing management resources (man, machine, material, method and measurement).
- 6. Kaizen Philosophy • Productivitycomes from elimination of waste. • Attack the root cause of the problem and not the symptoms. • Involve all – from the general to the sanitary orderly. • Acknowledge that humans are all mortals.
- 7. Basic Concepts What isKAIZEN? • The term of KAIZEN has been known as “Japanese art of continuous improvement (CI)” • “KAIZEN” is an activity to improve productivity by recognizing the existing situation and solving the problems of the organization continuously and gradually utilizing existing management resources (man, machine, material, money and information). Continuous improvement • utilizes experiences and know how accumulated in the organization • introduces and utilizes various easy-to-understand management technology • is implemented by total participation • does not require a big capital investment • does not require innovative engineering technology
- 8. KAIZEN KAI ….. CHANGE ZEN …. GOOD (FORTHE BETTER) KAIZEN….. CONTINUAL IMPROVEMENT
- 9. KAIZEN approach • Productivity •Quality • Time • Innovation
- 10. Steps in Kaizen •Utilizes experiences and know how accumulated in the organization • Introduces and utilizes various easy-to-understand management technology • Is implemented by total participation • Does not require a big capital investment • Does not require innovative engineering technology •
- 11. Steps in Kaizen •Prepare to start - trg, tools, improvement processes • Pilot • Replicate • Integrate TQM • Start a new cycle
- 12. Principles of Kaizen •Develop the strong point rather than remove the weak point. • Perform management of priority by ABC analysis. • Perform three-real ism. • Discuss what is wrong rather than who is wrong based on the data.
- 13. Principles of Kaizen •Use the method which even the least skilled person can do. • Practice visual control. • Accept the failure as the result of efforts. • Think while running and run while thinking.
- 14. Principles of Kaizen •Consider the efficiency and effect of Kaizen. – Relation with materials – Relation with machine and equipment – Relation with method – Relation with workers – Relation with time – Relation with type of product
- 15. Theme of KAIZEN: Analyzethe cause of low achievement ratio and improve it. Gap between the target and the actual operation result • Q: Isn’t fraction defective higher than expected? • C: Cost is competitive? • D: Aren’t there delay in delivery? • S: Labor accidents happen from time to time? • M: Absence rate is not high? • P: Does production quantity match the demand?
- 16. Theme of Kaizencont….. • Check of P, Q, C, D, S, M Material Machine Method • Check of Material, Machine, Man, Method Man to carry several corrugated boxes of 20kg. Means of transportation: 1. What is your most important job? (Big item oriented) 2. Is it going well? (Necessity of check) 3. How do you measure whether it goes well or not? (Necessity of measurement)
- 17. KAIZEN tools Systematic approachmeans an activity based on the following points. 1. Tackle the problem systematically and from the point of entire situation of the company. 2. Utilize both inductive approach and deductive approach. 3. Utilize some simple IE (Industrial Engineering) technique and QC tools as well as basic problem solving techniques, such as 5S, to improve productivity and quality. 4. Improve competitiveness of the company by continuous activity and horizontal development.
- 18. The Five MainElements of Kaizen • Teamwork • Personal discipline • Improved morale • Quality circles • Suggestions for improvement
- 19. Benefits • Elimination ofwaste (muda) and incorporation of efficiency • The kaizen five - S framework for a well organized shop floor – Seiri - tidiness – Seiton - orderliness
- 20. Benefits – Seiso -cleanliness – Seiketsu - standardized clean-up – Shitsuke - discipline • Standardization
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- 22. PLAN • Establish theobjectives and processes necessary to deliver results in accordance with the expected output. By making the expected output the focus, it differs from other techniques in that the completeness and accuracy of the specification is also part of the improvement
- 23. DO • Implement thenew processes. Often on a small scale if possible.
- 24. CHECK • Measure thenew processes and compare the results against the expected results to ascertain any differences.
- 25. ACT • Analyze thedifferences to determine their cause. Each will be part of either one or more of the P-D-C-A steps. Determine where to apply changes that will include improvement. When a pass through these four steps does not result in the need to improve, refine the scope to which PDCA is applied until there is a plan that involves improvement.
- 26. PLAN PLAN DO DO ACT ACT CHECK CHECK PDCA (DEMING’S)QUALITY PDCA (DEMING’S) QUALITY CYCLE CYCLE TIME TIME I I M M P P R R O O V V E E M M E E N N T T
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Editor's Notes
- #5 Change agents in any society are either Executed Excommunicated Branded madmen Jesus Capt