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Improvement
Start
Study process
flowchart
Identify problems
and wastes
Apply 5S for
workplace
Remove 3 MUs
Revise
standardized
methodologies
Figure 8.2 Applying Kaizen
KAIZEN BLITZ-BENEFITS
Table 8.5 Benefits of Kaizen Blitz
Criteria Before After % Improvement
VA Ratio 0.2% 3.5% 94%
WIP 1044 150 85%
Manufacturing 305 m2 252 m2 17%
Set Time 70 mins. 45 mins. 35%
Lead Time 13 days 0.6 days 95%
Distance Turn/Drill 35 m 4.5 m 87%
Travelled Drill/Weld 186 m 20 m 89%
Turn/Weld 160 m 5m 96%
Weld/Test 10 m 4m 60%
Transactions 82 0 100%
Worldwide Business Solutions
5S PRACTICES
Kaizen is a carefully evolved strategy by Japanese for improved
competitiveness of business. It is more than just a tactical weapon. It is also
a collection of tools. The Kaizen toolbox includes the 5S for improving
workplace effectiveness. 5S is rather than a management tool focused on
fostering and sustaining high quality housekeeping.
The 5S practices are:
(i) Sort
(ii) Straighten
(iii) Scrub
(iv) Systematize
(v) Standardize
The Japanese equivalent names for the five practices start with the
alphabet ‘S’. Thus, these are known as 5S practices.
TABLE 8.6 5S TOOLS
1. Seiri (sort) Separate out all unnecessary things and eliminate them.
2. Seiton (straighten) Arrange the essential things in order, so that they can be easily accessed.
3. Seiso (scrub) Keep machinery and working environments clean.
4. Seiketsu (systematize) Make cleaning and checking as a routine practice.
5. Shitsuke (standardize) Standardize the previous four steps.
1. Seiri – Sort
The objective of Seiri is to sort and throw away unnecessary items.
separate tools, machinery, products, inspections, work in progress, and documentation
into necessary and unnecessary and discard unnecessary items.
2. Seiton – Straighten
The purpose of this tools is to arrange necessary items in a neat, proper manner so that
they can be easily retrieved for use and to return them to their proper locations after use.
3. Seiso – Scrub
The objective of Seiso tool is to clean and inspect the respective work places thoroughly,
so that there is no dust on the floor, machinery and equipment. Keep machinery and work
environment clean.
4. Seiketsu – Systematize
The objective of this tool is to maintain high standards of workplace organization by
keeping everything clean and orderly at all times. Develop routine practices for cleaning
and checking.
5. Shitsuke – Standardize
The objective of the last 5S tools is to make the previous four steps part of
the daily routine and to observe self-discipline through continuous practice.
Follow procedures and standardize continuously to improve processes and
reestablish standards.
THE SEVEN DEADLY WASTES
Waste cannot be totally eliminated but can be reduced to the minimum. Toyota, the
Japanese automobile manufacturer, identified the following seven types of wastes as
the most common in industries.
Waste from overproduction
Waste of waiting time
Transportation waste
Processing Waste
Inventory waste
Waste of motion
Waste from product defect
BUSINESS PROCESS REENGINEERING (BPR)
What is BPR?
BPR is undertaken essentially to result in a quantum jump in performance
of processes. BPR is synonymous with innovation because it is more than
just automating or applying Information Technology to the existing processes
or operation.