Tqm kaizen
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Kaizen refers to continuous improvement processes that focus on incrementally improving processes, eliminating waste, and standardizing best practices. The key aspects of Kaizen include: - Incremental improvements made at little or no cost through employee involvement rather than major innovations. - Eliminating waste and non-value added activities through techniques like 5S and identifying the seven forms of waste. - Standardizing processes and documentation to preserve knowledge and measure performance. - An emphasis on teamwork, communication, and addressing issues systematically through approaches like Poka-Yoke for mistake proofing.
Tqm kaizen
- 2. Kaizen Kaizen ( 改善 ), Japanese for "good change". It has been applied in healthcare, psychotherapy , life-coaching, government, banking, and other industries Kaizen is the process of continuous improvements in small increments that make the process more effective ,efficient, controllable and adequate Improvements are usually accomplished at little or no expense with out sophisticated techniques or expensive equipments It focuses on simplification by breaking down complex processes into their sub-processes and then improving them.
- 3. Managerial practices ,which must broaden its perspectives, whilst increasing its involvement Shifting values ,which are socially and culturally adrift as quality is concerned Organizational effectiveness-the agenda of leadership, motivation and goal setting Kaizen-Main objectives
- 4. Kaizen KAIZEN (continous improvement) KAIZEN (continous improvement) Process driven Total employee involvement Good labour management relations Effective leadership, cross communication Adaptability to changing environmentVisibilty and control Reducing waste Customer orientation Standardization Quality awareness, quality control
- 5. Three Basic principles of Kaizen • Work place effectiveness – Japanese developed 5S tools for addressing the effectiveness • Elimination of waste , strain and discrepancy – Elimination of three MUs. The wastes are not free, but have been paid for the organization, since those produce wastes also get paid and material wasted costs money. There for one has to minimize and eliminate the waste in the organization Sl.NO Japanese Name Meaning 1 Muda Waste 2 Muri Strain 3 Mura Discrepancy
- 6. • Standardization : Kaizen stresses standardization of process, materials , machinery etc… with the following objectives Represent the best, easiest, safest way to carry out a job in the form of operating procedures and work instructions Represent the best way to preserve know-how and expertise Measure performance and standardize the same Standardize the procedures for maintenance Standardize the training program Standardize the audit for diagnosing the problem Standardize the procedures for preventing occurrence of errors and minimizing the variability
- 7. Value-added and non-value added work activities Muda, which refers to the seven classes of waste –over production,delay,transportation,processing,inventory,wasted motion and defective parts Principles of material handling Principles of motion study Documentation of standard operating procedures The five S’s for work place (Five S frame work for good house keeping) Seiton –Tidiness/Proper arrangement Seiri - Orderliness Seiso –Clarity Seiketsu- Personal cleanliness Shitsuke - Discipline Kaizen improvement focuses on the use of
- 8. Better communication through visual displays such as posters, bulletins etc. Just in Time principles Team effort on problem solving, conflict reduction and communication. Kaizen improvement focuses on the use of
- 9. 5s principle Seiko(Tidiness/Proper Arrangement) Identification of materials ,equipments and tools, data and information which are necessary, not necessary, discarding or giving another destination to unnecessary items and necessary space for required or necessary items. Seiton(orderliness) It is not only essential to tidy the place but also arrange them in the orderly manner. Seiso(Cleanliness) A part from a place being tidy and orderly it should be clean The shop floor should free of wastage, oil spills ,wastes etc.
- 10. Seiketso(Personal cleanliness) This point talks about maintaining good sanitary conditions and maintaining good personal hygiene Only a clean place can be conscious enough about keeping his work place clean and tidy. Information cleanliness: communications should be clear ,objective, easy to read and understand. Shitsuke(Discipline) Discipline in every job a person does This is not restricted to job related to organization but also personal work 5s principle
- 11. Poka-Yoke Japanese term means mistake proofing. The term adopted Shigeo Shingo as part of the Toyota production system The idea is to identify areas in which errors are likely to occur ,then introduce a number of devices that are a safe mechanism for preventing the error in the first place. Instead of sampling ,self inspection is promoted and following that, the person next in receiving line also checks the item before working on it.
- 12. Automatic transmissions: the inability to remove a car key from the ignition switch of an automobile if the automatic transmission is not first put in the "Park" position, so that the driver cannot leave the car in an unsafe parking condition where the wheels are not locked against movement. 3.5" floppy disks: the top-right corner is shaped in a certain way so that the disk cannot be inserted upside-down. SIM (Subscriber Identity Module) cards: The SIM card used in cellular phones has its upper left corner trimmed diagonally to guide the card correctly into position. Examples of Poka -yoke in consumer products
- 13. Poka yoke in Manufacturing • Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. • For example, a jig that holds pieces for processing might be modified to only allow pieces to be held in the correct orientation • A digital counter might track the number of spot welds on each piece to ensure that the worker executes the correct number of welds
- 14. Continuous Improvement rather than Innovation Innovation Kaizen Creativity Adaptability Individualism Teamwork, systems-approach Specialist-oriented Generalist-oriented Technology-oriented People-oriented Information: closed and proprietary Information:Open,shared Functional Orientation Cross-functional orientation Seeks new technology Building on existing technology Limited feedback Comprehensive feedback
- 15. Comparison of Kaizen and Innovation over Time Time BusinessSuccess Innovation Kaizen Innovation+Kaizen