1.kaizen basics @ scmld pgpel tri1 pt 1 18 jul 11

8/4/2019 1.Kaizen Basics @ SCMLD PGPEL Tri1 Pt 1 18 Jul 11

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2011 Kaizen

KAIZEN BASICS- Need for

Kaizen In Everyday Business Life

Kaicho Masaaki Imai


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2011 Kaizen

W Welcome !

KAIZEN Basics & Need for Kaizenfor Trainees @ PGPEL-Tri 1,

SCMLD

18th Jul 11


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= KAI = CHANGE

= ZEN = GOOD

(FOR THE BETTER)

= KAIZEN =

CONTINUAL IMPROVEMENT


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2011 Kaizen

KAIZEN Journey

S

DC

A

S: StandardizeD: DoC:CheckA:Act

P

DC

A

S

DC

A

P: PlanD: DoC:Check

A:Act


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2011 Kaizen

KAIZEN is: Focused Improvement.[Improvement is different from FocusedImprovement]

Paper does notburn in sunlight

Paper burns

Improvement

Focused

Improvement

mprovement is like sunlight:

Lot of energy, but dispersed (wasted)Small improvementsSlow progress.

Focused improvement concentrates theenergy:

Little energy, but concentrated andaligned Enables significant (large)improvements Small time required Rapid progress

KAIZEN


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2011 Kaizen

Isnt KAIZEN supposedto be

small improvements?

Kaizen is small changethat leads to

Large Improvement

KAIZEN: Succession of

small changes (steps)

that result in

large improvement


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2011 Kaizen

UTILITY COST PER CAR

42%

30%

13%

72%

1.5% 4.5%

9%

20%

8%

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

C

O

S

T

I

N

%

OTHERS

Shop C

Shop B

Shop A

POWER

FUEL

AIR

STEAMWATER KAIZEN (FI) Project

should focus here

KAIZEN is:IDENTIFYING STRATEGICALLY IMPORTANT AREA AND IMPROVING THERE


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2011 Kaizen

Improvement with

involvementgives sustainability

AIZEN is: making Sustainable Improvements

Studymachines & methods

Involve people inimprovement process

Involve managers inimprovement process

Managers mustsustain improvements by

practicing SDCA cycle

S

DC

A S:StandardizeD: DoC:CheckA:Act


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2011 Kaizen

What really is KAIZEN?

Kaizen is process improvement:

which is significant (large) done in strategically important areasspeedily in sustainable manner

using data, not opinionusing tools & techniques not anyhow


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2011 Kaizen

GEMBA

GEM + BA

means means

Real + Place

GEMBA is where :

Real Work Is Done

Value Is Created

Problem Is Solved


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2011 Kaizen

Organization for Kaizen

Customer

expectations

G e mb a

Organizati

onto

support

Customer

satisfaction


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2011 Kaizen

PDCA

The Improvement Cycle

PlanAct

Check Do


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2011 Kaizen

1.Go to gemba

2.Check gembutsu, collectdata

3.Take temporarycountermeasure on the spot

4.Diagnose Root Cause5.Standardize to prevent

recurrence

5 Golden Rules of Gemba Management


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2011 Kaizen

MUDAMUDA

Things to Remember about Waste:

MUDA is really a symptom rather than a root causeof the problem

MUDA points to problems within the system

(At both process & value stream levels)

Elements of process- that add time, effort, cost,butno value


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2011 Kaizen

Essence of KAIZENPhilosophy

Kaizen focuses onKaizen focuses on--

Muda


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2011 Kaizen

Conventionchases this !

Essence of KAIZENPhilosophy

Attack firstDont attack; it

is useful !

Kaizen acts on-Kaizen acts on- Muda


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2011 Kaizen

TYPES EXAMPLES

1) Defects Scrap, rework, replacement , inspection

2) Waiting Stock-outs, lot processing delays, equipment

downtime, capacity bottlenecks

3) Processing Unnecessary or incorrect processing

4) Overproduction Manufacturing the Items in anticipation, for which

there are no orders, no requirement from internal /

external customers

5) Motion Human motions that are unnecessary or straining

6) Inventory Excess - Raw Material or WIP or Finished Goods

7) Transport Carrying WIP to long distances, inefficient transport

7 Types ofMuda In Processing


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2011 Kaizen


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2011 Kaizen

Happens onlysometimes? Mura!

Happens to only

some people?Mura!

Happens onlysome places?Mura!

-Ask Why fivetimes

-Use diagnosticmethod like

Mura - Inconsistencies


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2011 Kaizen

Mura - Inconsistencies

EXAMPLE

All Quality Problems are examples of MURA


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2011 Kaizen

Muri - PhysicalStrain

Bend to work?Muri !

Noisy? Muri !

Polluted air? Muri !

Vibrating machine?

Muri !


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2011 Kaizen

Kaizen ActionSequence

Always I. R. E. :

MUDA First

MURA Next

MURI Last


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2011 Kaizen

1.kaizen basics @ scmld pgpel tri1 pt 1 18 jul 11

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