Kaizen_ presentation
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Kaizen is a Japanese philosophy of continuous improvement involving all employees. It focuses on identifying and eliminating sources of waste through small, incremental changes. Some key points of Kaizen include focusing on eliminating waste and non-value-added activities, using data-driven improvements, and empowering all employees to propose changes. The goal is to make continuous process improvements that deliver large benefits through numerous small changes.
Kaizen_ presentation
- 1. Presentation on "Kaizen- Implementation” ‘An Idea can change the way to work’ Date:-
- 2. Definition of Kaizen: “A system of continuous Improvement in which instances of muda(waste) are eliminated one by one at minimal cost. This is performed by all employees rather than by specialists.” Kaizen is process improvement which is significant, done in strategically important areas, speedily , in sustainable manner by using data, not opinion. & using tools & tech.. not anyhow. Basically kaizen is for small improvements, but carried out on a continual basis & involve all people in the organization. The principle behind is that a very large no. of small improvement are more effective in an organizational environment than a few improvements of large value. By using a detailed & through procedure we eliminate losses in a systematic method using various kaizen tools. This activities are not required to production area only & can be implemented in admin areas also. ‘An Idea can change the way to work’
- 3. Definition of waste : “Waste is any step or action in a process that is not required to complete a process (called “Non Value-Adding”) successfully. When Waste is removed, only the steps that are required (called “Value-Adding”) to deliver a satisfactory product or service to the customer remain in the process.” Type of wastes : ‘An Idea can change the way to work’
- 4. Kaizen Umbrella Concepts: ‘An Idea can change the way to work’
- 5. Get rid of all old (false) assumptions. Don’t look for excuses , look for ways to make it happen… Don’t worry about being perfect. Even if you only get it half right “ start now”! It does not cost money to do kaizen. If something is wrong “ fix it now”. Good ideas flow when the going gets tough. Ask “why” five times –get to the root. Look for wisdom from 10 people rather than one. Never stop doing Kaizen. Kaizen ( Improvement) principles: ‘An Idea can change the way to work’
- 6. Kaizen Target: “Achieve & sustain zero losses with respect to minor stops, measurement & adjustments, defects & unavailable downtimes.” Kaizen Policy: Practice concepts of zero losses in every sphere of activity. Relentless pursuit to achieve cost reduction targets in all resources. Relentless pursuit to improve overall plant equipment effectiveness. Extensive use of P.M. analysis as a tool for eliminating losses. Focus of easy handling of operators. ‘An Idea can change the way to work’
- 7. of Kaizen: Kaizen involves every employee in making change in most cases small, incremental changes. It focuses on identifying problems at their source, solving them at their source , & changing standards to ensure the problems stays solved. Kaizen reduces waste in areas such as inventory , waiting times, transportation , worker motion , employee skills, over production ,excess quality & in processes. Kaizen improves space utilization , product quality , use of capital , communications, production capacity & employee retention. Kaizen provides immediate results. Instead of focusing on large , Capital Intensive improvements, Kaizen focuses on creative investments that continually solve large numbers of small problems. ‘An Idea can change the way to work’
- 8. 1. Defects – Products or services that are out of specification that require resources to correct. 2. Overproduction – Producing too much of a product before it is ready to be sold. 3. Waiting – Waiting for the previous step in the process to complete. 4. Non-Utilized Talent - Employees that are not effectively engaged in the process 5. Transportation – Transporting items or information that is not required to perform the process from one location to another. 6. Inventory – Inventory or information that is sitting idle (not being processed). 7. Motion – People, information or equipment making unnecessary motion due to workspace layout, ergonomic issues or searching for misplaced items. 8. Extra Processing – Performing any activity that is not necessary to produce a functioning product or service. Type of wastes : ‘An Idea can change the way to work’
- 9. Waste Definition Office Example Manufacturing Example Defect Work that contains errors or lacks something necessary • Incorrect information being shared • Data entry errors • Forwarding incomplete documents • Scrap • Rework • Missing parts Overproduction Producing more materials or information than customer demand • Creating reports no one reads/needs • Making extra copies • Providing more information than needed • Producing more products than demand • Batch process resulting in extra output • Having a “push” production system Waiting Idle time created when material, information, people or equipment is not ready • Ineffective meetings • Waiting for meetings to start • Files awaiting signatures/approvals • Waiting for tools, parts, information • Broken machines waiting to be fixed • Raw materials not ready Not Utilizing Talent Not, or under, utilizing the talent of employees • Insufficient training • High absenteeism and turnover • Inadequate performance • Employing people in the wrong position • Not fully training employees • Missing improvements by failing to listen to employees Transportation Movement of materials or information that does not add value • Hand carrying paper to the next process • Delivering unneeded documents • Going to get signatures • Moving products around before shipping • Moving product from different workstations • Moving inventory around to take stock Inventory Excess materials on hand that the customers or employees do not need right now • Purchasing excessive office supplies • Searching for computer files • Obsolete files or office equipment • More finished products than demand • Extra materials taking up work space • Broken machines sitting around Motion Movement of people that does not add value • Searching for files • Walking/reaching to get materials • Sifting through inventory to find what is needed • Reaching to make adjustments • Walking to get a tool multiple times • Repetitive movements that could overwork/injure an employee Extra Processing Efforts that do not provide value from the customer's perspective • Unnecessary signatures on a document • Making more copies of a document than will be needed • Saving multiple copies of the same file in multiple locations • Adding unneeded value to a product • Using a more high-tech machine than needed • Extra steps to correct avoidable mistakes ‘An Idea can change the way to work’
- 10. Example : Before Waste is removed, processes are often scattered, which can negatively affect your customers: Before Waste is removed in a kitchen (Sandwich making process example). ‘An Idea can change the way to work’
- 11. Example : After Waste is removed in a kitchen (Sandwich making process example). After Waste is removed, processes are more streamlined, resulting in more satisfied customers. You’ll also save your organization time and money: ‘An Idea can change the way to work’
- 12. Question & Answer Session :- ‘An Idea can change the way to work’
- 13. Prepared By:- Pranav B. Gujjar ‘An Idea can change the way to work’