KAIZEN

AGENDA

 Introduction
 Introduction: Man Behind Kaizen
 Introduction: Who does Kaizen? Why ?

 Kaizen Methodology
 Gemba Kaizen
 1. Housekeeping
 2. Muda elimination
 3. Standardization

 Toyota Example
 Summary/Benefits of Kaizen

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 INTRODUCTION: MAN BEHIND KAIZEN

 Masaaki Imai is known as the developer of

Kaizen. He is known as the “Lean Guru” and
the father of Continuous Improvement

 According to him In simple words Kaizen

means improvement. Kaizen strategy calls
for never-ending efforts for improvement
involving everyone in the organization –
managers and workers alike.

 Author of books like Kaizen(1986)Key to

Japans Competitive success and Gemba
Kaizen(1997)
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http://en.wikipedia.org/wiki/Masaaki_Imai
 INTRODUCTION: WHO DOES KAIZEN ? WHY ?
 WHY ?
 Maintenance
 Objective of the maintenance
function is to maintain current
technological, managerial, and
operating standards
 Innovation
 Improvement function is aimed at
improving current standards.

 WHO ?
 Kaizen
Ongoing improvement involves
everyone
 Top management

 Managers

 Workers 4

http://www.kaizen.com/
 KAIZEN METHODOLOGY

 Finding out the pain area

 Analysis of the pain area

 3M„s Considered with the 4M„s

 3M‟s  MURA, MURI, MUDA

 muda ("non-value-adding work")
 muri ("overburden")
 mura ("unevenness")

 4M‟s  MAN, MACHINE, MATERIAL, METHOD

http://en.wikipedia.org/wiki/Kaizen
 TYPES OF WASTES
• Mura(Unevenness) is avoided through Just In Time
systems which are based on little or no inventory, by
MURA supplying the production process with the right part, at
the right time, in the right amount

• Muri(overburden) can be avoided through

MURI standardized work. To achieve this a standard
condition or output must be defined to assure effective
judgment of quality.

• Muda(non-value-adding work) Can be avoided by

MUDA identifying and eliminating non value adding and
unnecessary activities

http://en.wikipedia.org/wiki/Lean_manufacturing#Types_of_waste
 GEMBA KAIZEN
 Gemba is a Japanese word meaning 'real place,' where the
real action takes place. In business, Gemba is the „shop
floor‟ or „production place‟ where the value-adding activities
to satisfy the customer are carried out.

 3 Ground rules for practicing Kaizen in Gemba are: -

1. Housekeeping,
2. Muda elimination.
3. Standardization.

http://www.gemba.com/
 1. HOUSEKEEPING
5S is a method for organizing a
workplace, especially a shared workplace
(like a shop floor or an office space), and
keeping it organized.

To take the concept of Kaizen

performance to its ultimate level of
simplicity, it offered the following "5S" steps

Sorting- keeping only essential

items
Simplifying - Eliminates extra
motion.
Sweeping- keep the workplace
clean
Standardizing -Standardized work
practices
Sustaining - Maintaining and 8
reviewing standards

http://www.gemba.com/
 2. MUDA ELIMINATION

http://www.gemba.com/
 3. STANDARDIZATION

 Standards may be defined as the best way to do the job

 Products or services are created as a result of a series

of processes. Certain standard must be maintained at
each process in order to assure quality.

 Standards also can prevent recurrence of the same

problem

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http://www.gemba.com/
 TOYOTA EXAMPLE

 Management Philosophy

Respect for People &
Continuous Improvement

 The success of the Toyota

Production System can be
attributed to
 Eliminating wasted time and
resources
 Building quality into workplace
systems
 Finding low-cost but reliable
alternatives to expensive new
technology
 Perfecting business processes
 Building a learning culture for
continuous improvement

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Source : The Toyota Way, Jeffrey K. Liker

 BENEFITS OF KAIZEN
 Kaizen Reduces Waste like
inventory waste, time
waste, workers motion
 Kaizen Improves space
utilization, product quality
 Results in higher employee moral
and job satisfaction, and lower
turn-over.
 Toyota is well-known as one of the
leaders in using Kaizen. In 1999 at
one U.S. plant, 7,000 Toyota
employees submitted over 75,000
suggestions, of which 99% were
implemented.
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http://en.wikipedia.org/wiki/Kaizen
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QUESTIONS PLEASE !