0 kaizen what

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Kaizen (What is it ?)Kaizen (What is it ?)Kaizen (What is it ?)Kaizen (What is it ?)

Lean Foundations

Continuous Improvement Training

Lean Foundations




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Measure

Analyze

Improve

Control

Define

Continuous Improvement ProcessContinuous Improvement ProcessSix

SigmaProject

Six

SigmaProject KaizeneventKaizenevent

5S

event

5Sevent

Workplaceorganization

Workplaceorganization

Rapid Implementation of Known Solution

Rapid Implementation of Known Solution

Problem solvingProblem solving

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KAIZENKAIZEN

WHAT IS ITσ Kaizen is a tool originally used by Toyota to foster

continued improvement within its Toyota Production

System.σ It began as "Quality Circles," a means of factory shop

floor employees solving quality issues within a structuredteam framework, using specific new tools.

σ It is now used around the world by many companies andhas been adapted to suit their individual needs andcustoms.



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KAIZENKAIZEN

WHAT IS ITσ Kaizen in the United States usually refers to an event of

from three to five days of intense improvement activitiesdirected at a specific area of a business.

σ It is a process based on improving Safety, Quality, andDelivery, by the elimination of waste (muda) in its manyforms.

σ Its main tools are the implementation of σ

One Piece Flowσ Working to Takt Timeσ Developing a Pull System



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KAIZENKAIZEN

WHAT IS ITσ Kaizen events are a way of accelerating

improvementsσ to improve worker productivity,σ helping management to find new ways to gain

substantial savings in time, space and labor output.σ to collapse lead times,σ reduce work-in-process dramatically,σ reducing scrap and defects while minimizing the need

for capital expenditures.



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KAIZENKAIZEN

σ

A typical 3-5 day Kaizen events consists of:σ Team training (1/2 day)

σ Lean overviewσ Structure of Kaizen event

σ Team conducts Kaizen on the factory floor / area

(2-1/2 to 3-1/2 days)σ Identifying problemsσ Defining current processσ Observing, sketching process and collecting dataσ Brainstorming suggestions for improvementσ Implementing solutions (Rearrange equipment, Modify

machines, change methods, etc)



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KAIZENKAIZEN

σ Team measures improvements and verifiessolutions (1/2 day)

σ Team presents results to management, co-

workers and shop floor personnel (1/4 day)



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KAIZENKAIZEN

σ Kaizen is a way of unlocking the talentsand abilities of workers and allowdecisions to be made

σ at the operating level in the organization,σ in the quickest time,σ by the people that know the situation the best.



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KAIZEN EventKAIZEN Event

Type of Projectsσ Eliminate long conveyor assembly lines with cellsσ Combine operationsσ Reduce setup times - SMEDσ Reduce lot sizes, reduce WIPσ Determine proper tooling needed and organizeσ Visual factoryσ 5S onlyσ Establish new metrics

σ Load level scheduleσ Implement new product



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Type of Projects

σ Increase or decrease production based on new takt timeσ Change the processσ Change from automated process to manualσ Move from one location to another σ Safety Improvementsσ Maintenance Programs or machine overhaulσ Process improvement



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Type of Projects?

σ What type of problem or issue might youutilize a Kaizen event for ?



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Kaizen (What is it ?)Kaizen (What is it ?)Kaizen (What is it ?)Kaizen (What is it ?)

Lean Foundations


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