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KAIZEN - Adibah Kamal

KAIZEN slide for you to show and share with the other employee about the benefits implementing KAIZEN at your workplace.

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Dib K
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87 views20 pages

KAIZEN - Adibah Kamal

KAIZEN slide for you to show and share with the other employee about the benefits implementing KAIZEN at your workplace.

Uploaded by

Dib K
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Kaizen in

Lean
Manufacturing
Prepared by:
Adibah Kamal
HSE
What is Kaizen?
• KAIZEN = Continuous improvement
• Kaizen is a system of continuous improvement in quality, technology,
process, company culture, productivity, safety and leadership.
• Involves setting standards and the continuously improving those standards.
• Improvement WITHOUT SPENDING too much of money BUT INVOLVE
EVERYONE in the organization start from the Top Management, Middle
Management and Lower Management.
• Using simple common sense.
• On-going effort and never ending.

2
Did you know?
The philosophy of Kaizen is on the Toyota’s core values. It
means “continual improvement”. No process can ever be
declared perfect but it can always be improved. In practice it
means that everyone in the organisation is continuously looking
for ways to improve operations.

3 Kaizen 2023
Teamwork

What is the
Personal discipline

foundation Improved Morale

of kaizen
methods? Quality circles

Suggestions for Improvement


Why we need Kaizen?
To eliminate To increase To improve Customer
waste in productivity quality satisfaction
organization

To eliminate
Growth of
any Developing
the
abnormalities self
organization
& stopping of personality
limits
How to Kaizen?
• Identify the customer – requirement from the customer.
• Deming cycle – PDCA
1) Plan – identify what to change and how to do it.
Current state, future state, implementation plan
2) Do – execute the improvement.
3) Check – ensure the improvement works.
4) Act – future and on-going improvements
5) Repeat

6 Kaizen 2023
Identify the Customer
• Value added is always determined from
the customer’s perspective.
• Who is the customer?
• Every process should be focused on
adding value to the customer.
• Anything that does not add value is
waste.
• Some non-valued added activity is
necessary waste.

7
Identify the Current
State
• Crucial first step in process improvement.
• Deep understanding of the existing processes and
dependencies.
• Identify all the activities currently involved in
developing a new product.
• Observe the process first hand.
• Identify Value Added (VA), Non-Value Added
Required (NVA-R), and Non-Value Added (NVA).
• Generally creates more questions than answers.

8
Brainstorm and Analyze
• Kaizen team brainstorming to develop new process.
• Post improvement ideas on map or by category.
• Workflow
• Technology
• People/Organization
• Procedures
• Develop detailed future state map
• New workflow
• Value Add and Non- Value Add
• Cycle times
• Identify Kaizen “bursts” (immediate radical
change)

9
Implementation Plan
1. Think global / systems optimization.

2. Maximum impact to process.

3. Speed of implementation – create small victories

4. Cost- benefit analysis (CBA)

10 Kaizen 2023
Execute
1. Develop a concise, achievable milestone plan.

2. Communicate the plan to everyone.


- Supplier
- Team members
- Customers

3. Track activities in public

4. Celebrate small victories and publicly analyse failures.

11 Kaizen 2023
Check and Sustain
1. Meet regularly (weekly?) to review status of open implementation items.

2. Re-evaluate Future state regularly (quarterly?) for additional


improvement.

3. Track results on a public Kaizen Board.

12 Presentation title 20XX


Kaizen Blitz
also known as kaizen event, is a small but comprehensive and actionable effort to identify areas for improvement in a
business process and quickly implement recognized solutions effectively.

Total focus on a defined Day 4 : Implement the new


process to create radical AGENDA KAIZEN BLITS pricess
improvement in a short period (Plan, communicate,
of time. Day 1 : Setting the scene implement, modify)
Dramatic improvements in (Meet the team, training)
productivity, quality, delivery, Day 5 : Report and analyze
lead-time, set-up time, space Day 2 : Observe the current (Performance vs expectations)
utilization, work in process, process
workplace organization (Flowchart, identify waste,
identify root causes)
Typically five days (one week)
Day 3: Develop the future
long
state process
(Brainstorm and flowchart)

13 Kaizen 2023
14 Kaizen 2023
15 Kaizen 2023
Example Kaizen project

16 Kaizen 2023
17 Kaizen 2023
18 Presentation title 2023

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