gembakaizen-1281107579555-phpapp02

8/11/2019 gembakaizen-1281107579555-phpapp02

1/30

GEMBA KAIZENBy

Ismail Clement

http://gembakaizenemailconsulta

ncy.weebly.com/

1Gemba Kaizen Email

Consultancy


2/30

2

GEMBA KAIZEN

1. INTRODUCTION

2. GEMBA KAIZEN

3. HOW TO MANAGE

QCD IN GEMBA

4. STANDARDS

5. 5 S

6. MUDA

7. THE FOUNDATION OF

THE HOUSE OF

GEMBA

8. VISUAL

MANAGEMENT

9. SUPERVISORS ROLEIN GEMBA

Gemba Kaizen Email

Consultancy


3/30

3

CHAPTER ONE

INTRODUCTION

TOGEMBA KAIZEN

Gemba Kaizen Email

Consultancy


4/30

4

What is Kaizen?

Kaizen means change for the better in Japanese. The

best English equivalent is improvement'. Kaizen is

made up of two characters:

Gemba Kaizen Email

Consultancy


5/30

5

Where did kaizen

originate? Kaizen as we know it in Lean

Manufacturing originated at Toyota

Motor Company.

Many of the concepts and tools ofkaizen came from industrial

engineering and Dr. Edward

Deming's teachings. Masaaki Imai'sbook 'Kaizen' made it a common

word outside Japan back in the

1980s. Gemba Kaizen EmailConsultancy


6/30

6

DEFINITION OF LEAN

Lean manufacturing is a strategy inremaining competitive through the

endless pursuit of waste elimination.

1. Focus on the customer

Who are the external customer?

What is an internal customer?

What is the value to the customer?

Gemba Kaizen Email

Consultancy


7/30

7

CONT

2. Eliminate the 7 waste of production. What are the 7 waste?

What causes the waste?

How do we eliminate waste?

3. Do more with less

How can we increase value?

How to waste less resources?

How can we do both?

Gemba Kaizen Email

Consultancy


8/30

8

Is Kaizen a shop floor

thing? No. Kaizen is a way to improve any

process. Kaizen is about creating a

company culture that does not

tolerate waste. Kaizen effortstypically start on the Gemba (in

production or where the value is

added) and extend across the entireenterprise.

Gemba Kaizen Email

Consultancy


9/30

9

Kaizen is a Japanese word. What

if I dont want to use that word?

What you call kaizen doesnt matterso much as understanding what it is

and doing it right. Most people that

have a problem with the word kaizeneither haven't experienced what

kaizen really is or will never be

convinced anyway.

Gemba Kaizen Email

Consultancy


10/30


11/30

11

K IZEN

Is continuous improvement.

The KAIZEN philosophy - is our way of

life and should focus on constantimprovement efforts.

The improvements are small and

incremental. KAIZEN process are based on common

sense and low cost approaches.

RUSSIANGemba Kaizen EmailConsultancy


12/30

12

MAJOR KAIZENCONCEPTS

1. KAIZEN and management.

2. Process versus result.

3. Following the PDCA/SDCA.4. Putting quality first.

5. Speak with data.

6. The next process is the customer.

Gemba Kaizen Email

Consultancy


13/30

13

KAIZENAND MANAGEMENT

Has two major functions: Maintenance

and Improvement.

Maintenance: current technological,managerial and operating standards.

Improvements: activities directedtoward elevating current standards.

Gemba Kaizen Email

Consultancy


14/30

14

Japanese Perceptions Of Job

Functions

Top management

Middle management Improvement

Supervisors Maintenance

Workers

Gemba Kaizen Email

Consultancy


15/30

15

KAIZEN n TECHNOLOGY

Whenever money is a key factor,

innovation is expensive.

Kaizen emphasizes human efforts,

morale, communication, training,

teamwork, involvement and self disciplinea commonsense low cost approach to

improvement.

Gemba Kaizen Email

Consultancy


16/30

16

Improvement Broken Down Into

Innovation Top management Innovation

Middle management Kaizen

Supervisors Maintenance

Workers

Gemba Kaizen Email

Consultancy


17/30

17

PROCESS

VERSUS RESULT

Kaizenfosters process-oriented thinking.

Kaizenfocuses on human efforts A process-oriented approach should also be:-

PDCA

SDCA

QCD TQM

TPM

Kaizen

strategies have failed many companiessimply because they ignored process.

The most crucial element in the kaizen process is thecommitment and involvement of top management.

Gemba Kaizen Email

Consultancy


18/30

18

Following the PDCA/SDCACycles

The first step in the kaizen process

establishes the PDCA cycle.

Plan

refers to establishing a target forimprovement.

Dorefers to implementing the plan.

Checkrefers to determining whether theimplementation remains on track.

Gemba Kaizen Email

Consultancy


19/30

19

Cont.

Act refers to performing andstandardizing prevent recurrence of theoriginal problem or to set goals for the

new improvement. The PDCAcycle revolves continuously.

Management must initiate PDCAby

establishing continuously challenginggoals.

Before working on PDCA, any current

process must be stabilized.Gemba Kaizen EmailConsultancy


20/30

20

Cont.

Every time an abnormality occurs in thecurrent process, the following questionsmust be asked:

Did it happen because we did not have astandard?

Did it happen because the standard was

not followed?Did it happen because the standard was

not adequate?

Gemba Kaizen Email

Consultancy


21/30

21

Cont.

SDCAstandardizes and stabilizes the

current process.

PDCA

improves the current process. SDCA refers to maintenance and PDCA

refers to improvement, these become the

two major responsibilities ofmanagement.

Gemba Kaizen Email

Consultancy


22/30

22

IMPROVEMENT- PDCA

P

D

A

C

PL N

CT

DO

HECK

Gemba Kaizen Email

Consultancy


23/30

23

MAINTENANCE- SDCA

sA

DC

ST ND RDIZECT

DOCHECK

Gemba Kaizen Email

Consultancy


24/30

24

PUTTING QUALITY FIRST

Of quality, cost and delivery, which

should always have the highest priority?

? concept requires managementcommitment.

Managers often face the temptation to

make compromises in meeting deliveryrequirements or cutting cost.

Gemba Kaizen Email

Consultancy


25/30

25

SPEAK WITH DATA

KAIZEN is a problem solving process.

The problem must be understood and

recognized. Solving a problem without data is not a

very scientific or objective approach.

Collecting, verifying and analyzing datafor improvement is vital.

Gemba Kaizen Email

Consultancy


26/30

26

THE NEXT PROCESS IS THE

CUSTOMER

The next process should always be

regarded as the customer.

Refers to two types of customers: internaland external.

When everyone in the organization

practices this the external customer willreceive a high quality product or service

as a result.

Gemba Kaizen Email

Consultancy


27/30

27

MAJOR KAIZEN SYSTEM

The following major systems should be in place

in order to successfully achieve a Kaizen

strategy.

Total quality control / total quality management.A just in time production system.

Total productive maintenance.

Policy deployment.A suggestion system.

Small group activities.

Gemba Kaizen Email

Consultancy


28/30

28

TQC / TQM

One of the principles of Japanese managementhas been TQC in its early development.

This has evolved into a system encompassing

all aspects of management and is now referredto as TQMa term used internationally.

TQC / TQM should not be regarded as strictlyas a quality control activity: It has developed as

a strategy to aid management to be morecompetitive and profitable by helping it toimprove in all aspect of business.

Gemba Kaizen Email

Consultancy


29/30

29

Cont.

Q meaning quality, has priority but thereother goals toonamely cost anddelivery.

T signifies total, meaning that itinvolves everybody in the organization.

C refers to control or process control.

In TQC/TQM key process must beidentified, controlled and improved oncontinuously in order to improve results.

Gemba Kaizen Email

Consultancy


30/30

30

TQM

Quality assurance

Quality control

inspection

Aim for continuous improvement / Involve suppliers &

customers / Involve all operations / Performance

measurement / Team work / Employee involvement

Third party approval, systems audits, advanced

quality planning, involvement of non production

operations, failure mode and effect analysis,

statistical process control

Develop quality manual, process performance

data, self inspection, product testing, basic quality

planning, use of basic statistics, paper work

control

Salvage, sorting, grading, corrective actions,

identify sources of non conformance

Gemba Kaizen Email

Consultancy

gembakaizen-1281107579555-phpapp02

Documents