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KAIZEN

The Continuous Improvement

Programme.

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CONCEPT Kai means change

zen means good (for the better)

Then, Kaizen means change for the better

or continuous improvement

Gradual, orderly, and continuous

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What Does Kaizen Mean?

KAI ZENTo modify, to change Think, make good, make better

= KAIZENMake it easier by studying it, and making the improvementthrough elimination of waste.

+

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Unlock Your Potential

To Maximise Profits (or Stay in Business)

Eliminate Wasted Time

- Everywhere

Shrink Lead Times

- Gain a Competitive Edge

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FOCUS

Eliminating waste Systems & Processes

People Value on Individuals

Value collective creativity

Incorporates everybody Encourages anyone in thinking for ideas

Low Cost

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The Seven types of waste

Overproduction

Delays (waiting time)

Transportation

Process

Inventories

Motions

Defective products

7

Wastes

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Non Value AddedActivities

Examine all Non Value added

activities in the Job forelimination.

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Focus Kaizen on Reducing NVA

NVA Reduction is a Non Traditional Approach

MajorImpact on Lead Time and QCD

Value-Add Activity

Non-Value-Add Activity

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Improvement Ideas Japan: 24 improvement ideas in writing per

employee each year

U.S. companies: average less than one

United Kingdom: one idea every six years

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Are You Practicing Kaizen?

When you have a problem, do you

a) try to tackle the whole thing

or

b) divide it into small manageable pieces?

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Are You Practicing Kaizen?

Do you try to fix the problem

a) perfectly from the beginning

or

b) make little improvements along the way?

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Are You Practicing Kaizen?

Do you

a) never deviate or stray from the

procedures that you have been taught

or

b) think of alternative methods for getting

the work done?

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ISSUES Breaking the old habits

New ideas/logic

Cause of problem cultural

Gemba Place where real action occurs

Wet Blanket List

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THE WET BLANKET LIST I am too busy to study it

It's a good idea, but the timing is premature

It is not in the budget

Theory is different from practice

Isn't there something else foryou to do ?

I think it doesn't match corporate policy

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THE WET BLANKET LIST It isn't ourbusiness; let someone else think

about it

Are you dissatisfied with yourwork ?

It's not improvement, it's common sense

I know the result, even if we don't do it

I will not be held accountable forit Can't you think of a betteridea ?

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KAIZEN BUILDING BLOCKS 5 S

Standardization

Eliminate Muda

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Kaizen Implementation

Study the job in detail

Systematically examine all possibilities for

improvement using 5S, Poka Yoke, SMED

Lean etc. Submit yourideas in writing.

Accept a token reward.

Team WAVE examines the suggestion Implement and Kaizen prepared.

Accept reward in proportion to the profit.

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Kaizen

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Thank you