What is Kaizen?1.Originated from Japan.

2. Masaaki Imai- known as the developer of kaizen

3. Kaizen is the organized use of common sense to improve cost, quality, delivery, and responsiveness to customer needs.

4. Adapted by many firms all over world as a way of accelerating improvements.

ELEMENTS OF KAIZEN

1.Elimination of waste

2.5s methodology

3.Standardization

WASTES

1.OVERPRODUCTION

1.Pockets of excess inventory around plants.

2.Making excess products earlier in greater quantities than the

customer wants or needs.

3.Long production runs of the same part to avoid change over

and setup time.

2. TRANSPORTATION1. Process steps are far apart.2. Too many forklifts.

3. INVENTORY1.Product being made without orders.2.Obsolete inventory.3.Cost of racks.

4.OVER PROCESSING1.Over-processing occurs any time more work is done on a piece than what is required by the customer. This also includes2.Using tools that are more precise, complex, or expensive than absolutely required.

5. WAITING.1. Frequent chronic break downs2. Operators waiting inspectors for the product inspection3. Equipment changeover will take hours

6.DEFECTS/REWORK 1.doing the same job/task more than once.

7.MOTION 1.process steps located as functional lands with no

uniform flow.

2.Any motion which doesnot add value

• Less Labor Requirements• Less Space Requirements• Increased Flexibility• Decreased Costs• Improved Quality• Improved Responsiveness• Increased Innovation• Increased Employee Enthusiasm

EXPECTATIONS OF REDUCING

WASTES

5S METHODOLOGY

SEIRI (Sorting)

• Eliminate all unnecessary tools, ,parts, and instructions. • Keep only essential items • eliminate what is not required • prioritizing things per requirements • keeping them in easily-accessible places.• Everything else is stored or discarded.

SEITON (straightening or setting in order / stabilize)’

•There should be a place for everything and everything

should be in its place. •The place for each item should be clearly labeled or

demarcated. •Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. •Workers should not have to bend repetitively to access materials. •Each tool, part, supply, or piece of equipment should be kept close to where it will be used.

SEIKETSU (Standardizing)•Work practices should be consistent and standardized. •All work stations for a particular job should be identical. •All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station.• Everyone should know exactly what his or her responsibilities.

SEISO (Sweeping or shining or cleanliness / systematic cleaning)

• Clean the workspace and all equipment• At the end of each shift, clean the work area • be sure everything is restored to its place. • Spills, leaks, and other messes also then become a

visual signal for equipment or process steps that need attention.

• A key point is that maintaining cleanliness should be part of the daily work

SHITSUKE (Sustaining the discipline or self-discipline)

• Maintain and review standards. Once the previous 4 S's have been established, they become the new way to operate.

• Maintain focus on this new way and do not allow a gradual decline back to the old ways.

• thinking about yet better ways. • When an issue arises such as a suggested

improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.

• What Causes Substandard Plating Results? • Poor cleaning prior to plating• Improper plating solution maintenance• A lack of process and/or procedural controls• Impure anodes• Uncontrolled rectifier output• Not applying the proper undercoats• Poor cleaning and drying after plating

• Potential Problems That Can Occur • Bare spots (lack of coverage)• Pitting• Peeling or flaking layers• Rough surfaces• Underplating (Deposit(s) too thin)• Overplating (Deposit(s) too thick)• Dimensional tolerance issues• Inferior appearance• Bad solder joints• Shortened shelf life• Poor corrosion resistance• Hydrogen embrittlement

BENEFITS OF KAIZEN• Reduces waste- like inventory waste, time waste, workers motion. • Improves space utilization, product quality

• Results in higher employee morale and job satisfaction, lower turn-over.

• Widely acceptable-can be used in both manufacturing and non-manufacturing environments, for processes as well as people.

• Highly effective and success-oriented-Kaizen events will generate quick results, measurable results, establish the baseline and measure the change.

• A learning experience-every member of a Kaizen Team will walk away from the event learning something new

BASIC TIPS FOR KAIZEN ACTIVITIES

1. Discard conventional fixed ideas.2. Think of how to do it, not why it cannot be done.3. Do not make excuses. Start by questioning current

practices.4. Do not seek perfection. Do it right away even if for only

50% of target.5. Correct it right away, if you make a mistake.6. Do not spend money for KAIZEN, use your wisdom.7. Wisdom is brought out when faced with hardship.8. Ask 'WHY?" five times and seek root causes.9. Seek the wisdom of ten people rather than the knowledge

of one.10. KAIZEN ideas are infinite.