1.kaizen basics
TRANSCRIPT
2009 Kaizen Institute
KAIZEN® BASICS
Sensei Masaaki Imai
2009 Kaizen Institute
W Welcome !
KAIZEN® Sensitization Sessionfor Trainees @ MBA 1st Year,
SCMLD 1 May 09
= KAI = CHANGE
= ZEN = GOOD(FOR THE BETTER)
= KAIZEN =CONTINUAL IMPROVEMENT
2009 Kaizen Institute
KAIZEN Journey
S
DC
A
S: StandardizeD: DoC:CheckA:Act
P
DC
A
S
DC
A
P: Plan D: DoC:CheckA:Act
2009 Kaizen Institute
KAIZEN is: Focused Improvement.[Improvement is different from Focused Improvement]
Paper does not burn in sunlight
Paper burns
ImprovementFocused
Improvement
Improvement is like sunlight:• Lot of energy, but dispersed (wasted)• Small improvements• Slow progress.
Focused improvement concentrates the energy:• Little energy, but concentrated and aligned• Enables significant (large) improvements• Small time required• Rapid progress
KAIZEN
2009 Kaizen Institute
Improvement with involvement
gives sustainability
KAIZEN is: making Sustainable Improvements
Study machines & methods
Involve people in improvement process
Involve managers in improvement process
Managers must sustain improvements by
practicing SDCA cycle
S
DC
AS: StandardizeD: DoC:CheckA:Act
2009 Kaizen Institute
What really is KAIZEN®?
Kaizen is process improvement:• which is significant (large)• done in strategically important areas• speedily • in sustainable manner
using data, not opinionusing tools & techniques – not anyhow
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GEMBA
GEM + BA
means means
Real + Place
GEMBA is where :
•Real Work Is Done
•Value Is Created
•Problem Is Solved
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Organization for Kaizen
Customer
expectations
G e m b a
Organizationto
support
Customer
satisfaction
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PDCA
The Improvement Cycle
PlanAct
Check Do
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1.Go to gemba2.Check gembutsu, collect data3.Take temporary
countermeasure on the spot4.Diagnose Root Cause5.Standardize to prevent
recurrence
5 Golden Rules of Gemba Management
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MUDAMUDA
Things to Remember about Waste:
•MUDA is really a symptom rather than a root cause of the problem•MUDA points to problems within the system
(At both process & value stream levels)
Elements of process- that add time, effort, cost, but no value
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Essence of KAIZEN® Philosophy
Kaizen focuses on Kaizen focuses on --
Muda
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Convention chases this !
Essence of KAIZEN® Philosophy
Attack firstDon’t attack; it
is useful !
Kaizen acts on-Kaizen acts on-Muda
2009 Kaizen Institute
TYPES EXAMPLES
1) Defects Scrap, rework, replacement , inspection
2) Waiting Stock-outs, lot processing delays, equipment downtime, capacity bottlenecks
3) Processing Unnecessary or incorrect processing
4) Overproduction
Manufacturing the Items in anticipation, for which there are no orders, no requirement from internal / external customers
5) Motion Human motions that are unnecessary or straining
6) Inventory Excess - Raw Material or WIP or Finished Goods
7) Transport Carrying WIP to long distances, inefficient transport
7 Types of Muda In Processing
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2009 Kaizen Institute
• Happens only sometimes? Mura!
• Happens to only some people? Mura!
• Happens only some places? Mura!
-Ask “Why” five times-Use diagnostic
method like Kepner-Tregoe
Mura - Inconsistencies
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Mura - Inconsistencies
EXAMPLE
All Quality Problems are examples of MURA
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Muri - Physical Strain
• Bend to work? Muri !
• Noisy? Muri !• Polluted air? Muri !
• Vibrating machine? Muri !
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Kaizen Action Sequence
Always I. R. E. :MUDA First
MURA Next
MURI Last
2009 Kaizen Institute