ALWAYS

CONTINUAL

CHANGE

GOOD

IMPROVEMENT

FOR THE BETTER

KAIZEN: What it is?

1) Process Improvement

2) Observation

3) Use of New Paradigms

4) Short Time

5) Zero Investment

6) Human Development & Empowerment

7) Profits & Savings - Plenty

KAIZEN IS A JOURNEY FROM:

EVENT

RESULT

GROSS

ENFORMENT OF CHANGE

TO CAUSE

TO PROCESS

TO MICRO

TO INDUCEMENT OF CHANGE

KAIZEN IS CONTINUAL IMPROVEMENT

TIMETIMEIM

PRO

VE

ME

NT

IMPR

OV

EM

EN

T

KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE

OBSERVATION INTELLIGENCE

PHYSICAL EFFORT

PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA

GEMBA: PLACE OF WORK

GEMBA is where . . .

Value is added

Actual work is done to meet customer requirement

Problems are solved

Staff is responsible for providing support, not for giving instruction

The ‘S’ Japanese Word What is involved Objective

1SSEIRI

(Sorting Out)

Segregate necessary from unnecessary

Remove what is not required

Decide on frequency of sorting

Saving and recovering Space

2SSEITON

(Systematic Arrangement)

Arranging in order

Place for everything, Everything in its place

Minimizing search time

3SSEISO

(spic and Span)

Cleaning the work place/ equipment

Attaining the warning bell

Inspecting for problems

Taking corrective actions faster

4SSEIKETSU

(Standardization)

Working Methodology

(Procedures & WI)

Achieving higher productivity and better quality

5SSHITSUKE

(Self Discipline)Forming the habit in form of Training and Discipline

Doing it right at First Time

1 ‘S’Seiri

Sort for . . .

Not Needed at All

Needed but not Now

Needed but not here

Needed but not so much Quantity

1 ‘ S’

WANTED UNWANTED

1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1 ‘ S’ - SEIRI

2 ‘S’

Seiton

Arranging things in systematic way

Example: Jigs & tools

Anybody

Immediately

Can See

Can take out

Can return

Where – Fix the position

What – Fix the item

How Many – Fix the Qty

While fixing the position remember . It should be . . .

Climb Free

Bend Free

Search Free

Count Free

Air Free

FIFO

2 ‘S’ – In our body there is a fixed place for every organ.

2 ‘ S’ - SEITON

STEPS FOR IMPLEMENTATION OF SEIRI & SEITON

MAKE SPOT INSPECTION & ANALYSIS REGARDING UN-NECESSARY

& EXTRA ITEMS

GET RID OF UNNECESSARY THINGS, PROVIDE MINIMUM ADDITIONAL STORAGE FACILITIES

DECIDE WHAT WILL BE STORED WHERE- PLACE FREQUENTLY USED

ITEMS NEARBY AND IN-FREQUENTLY USED ITEMS IN SEPARATE PLACE.

LABEL STORAGE AREAS IN ORDER TO RETURN TO DESIGNATED

LOCATION NUMBER

RECORD STORAGE PLACE IN DIRECTION CHART

REVIEW AND INSPECTION

3 ‘S’

Seiso

KIKEN KITSUI KITENOI

Clean the surroundings !

(DANGER) (PROBLEM) (DIRT)

3 ‘ S’ - SEISO

3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

Clean Procedure:

Decide what to clean

Decide who is in charge of each cleaning

Decide on cleaning method

Prepare cleaning tools and equipment

Implement cleaning

EXAMPLE : PREPARE CHECKLIST FOR CLEANING

SL.No CHECKLIST TICK

1 Check Floors are clean

2 Check Work areas are clean

3 Check walls are clean

4 Check Pillars and Ceiling are clean

5 Check Windows are clean

6 Check Rooms and Electrical lights are clean

SEISO CYCLE

• BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.

• BEGINNING OF WORK - DO TRIALS AND START UP

• DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES

• AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS

• SEISO IS A PART OF GOOD WORKMANSHIP• SEISO IS AN IMPORTANT PRE-CURSOR WITH

5S

4 ‘S’

Seiketsu

WHAT TO DO STANDARDISATION . . .

Workstation layout,work area layout

Work in progress

Sequence of work

Material & tools used

Machine & their process parameters

Quality parameters, methods of measurement & reporting methods

5 W’s and 1 H

4 ‘S’ – In every human being the structure of fingers are same I.e Standardised. If it is not so, then we call it is

abnormal.

4 ‘ S’ - SEIKETSU

DEMING’S CYCLE

A P

DC

A S

DC

PDCA: Plan – Do – Check – Act

SDCA: Std – Do – Check – Act

A P

DC

A S

DC

A P

DC

A S

DC

A P

DC

A S

DC

TIME

IMP

RO

VE

ME

NT

DEMING’S CYCLE PROCESS

5 ‘S’

Shitsuke

ENSURE . . .

Procedure & Work Instruction are correct.

Standard are expressed in specific.

Visual Aids are used.

Train at all levels.

Work ethics for effective management.

Transparent & Discipline work culture.

5 ‘S’ – Every human body has its standard process which they maintain.

5 ‘ S’ - SHITSUKE

QUOTES

Make effort not an excuse

An error, doesn’t become a mistake until you refuse to correct it.

OTIFEF: On Time In Full Error Free

We don’t employ your hand & legs, we want your head & heart also.

Company is known from the people of company

“Chalak Nahi Malik Bano”