OXFORD COLLEGE OF ENGINEERING &MANAGEMENT

SEMINAR REPORT 0N KAIZEN

SUBMITTED BY RAIJUL HAQUEBRANCH MECHANICAL ENGGSEMESTER 7THREGD NO 1121342174UNDER GUIDENCE OFEr. SHIBASHISH PUROHITEr. SAROJ ROUT

Presentation flow• Introduction• Key Principles• Implementation Concept 5s , PDCA Cycle , Quality Circle , Kanban• Benefits• Drawbacks• Kaizen in Toyota• Example of Kaizen• Kaizen in Day to Day life• conclusion

Kaizen Introduction

• KAI means 'change' or 'the action to correct‘, ZEN means 'good'

• Kaizen means making changes for the better on a continual,never-ending basis.

• MASAAKI IMAI is the father of Kaizen.

• Foundation of Kaizen was laid in Japan after the second world war,when the country was attempting to rebuilt infrastructure and rethink many system

Kaizen : Key principles• Consider process & results • Need to look entire process & evaluate job as to

be best way • No one should blamed & best process is put into

place.

Kaizen team Problem solving team

Time 2 TO 10 Hour 3 TO 6 Month

Power Make change Recommend action

Focus Whole Process Single Issue

Kaizen : Implementation Concepts

 The term KAIZEN is based on some concepts as stated below

1. 5S (Seiri, Seiton, Seiso, Seiketsu & Shitsuke)

2. PDCA CYCLE (Plan,Do,Check,Act)

3. QUALITY CIRCLE

4. KANBAN

“5 S” in Kaizen

5 S is a method for organizing a workplace especially a shared workplace

1. “Seiri”(Sort):Keeping only essential items.

2. “Seiton”(Set in order):Eliminate extra motion

3. “Seiso”(Shine):Keep the work place clean

4.“Seiketsu”(Standardize):Standardize work practices

5. “Shitsuke”(Self discipline):Maintaining discipline

• PLAN

Collect the data

• DO Implementation

• CHECK

Evaluate the result

• ACT

Apply the change

PDCA CYCLE

QUALITY CIRCLES

• A quality circle is a volunteer group composed of employees, who are trained to identify, analyse and solve work-related problems and present their solutions to management

• This improves the performance of the organization

KANBAN• Kanban (signboard) is a concept related to lean and

just-in-time (JIT) production • It works as a communication system which

immediately provides information about changed demand through the entire supply chain

BENIFITS

1.Widely applicable.

2.High effective & result oriented

3.Higher operational efficiency

4.A learning experience

5.Higher employee moral and job satisfaction

6.Encourage worker to solve everyday problem

7.Acts as a motivator

8.Reduces breakdown

9.Eliminates the need of inspection

DRAWBACK

• Difficulties in getting started

• Getting people to think in long term

• Too much involvement needed from management

• Lack of proper procedure to implemented

• Toomuch suggestion may lead to confusion and time wastage

Kaizen in Toyota• In the earlier 1990,Toyota was facing acute labour shortage• toyota’s initial mangement focus was on increasing

production efficiency through higher production levels with less number of workers.this resulted in increased stress & worker exodus

• The global upsurge in car demand during 1987-1991 led to drastic increase in demand for labors

• Toyota realized that the it is the time to implement Kaizen for modifying existing assembly lines to attract workers

• The company decided to change its working conditions to accommodate workers of more diverse nature

• Toyota is well known one of the leaders in using Kaizen.In 1999 at one U.S plant 7000 toyota employee submitted over 75000 suggestions of which 99% were implemented

EXAMPLE OF KAIZEN

KAIZEN IN DAY TO DAY LIFE Consider the case of a student’s bag. The items can be

classified into 1.Notes and assignments 2.Stationary (pens, notepads etc.) 3.Other items like calculators, pen drive etc.

Regular checking of the stationary items ensures that the notemaking is not affected due to lack of stationary.

Keeping notes and assignments organized enables faster access to them.

Overall checking of bag at regular intervals ensures that no necessary items are missing

Conclusion

• The concept is simple but if properly applied can lead to significant efficiency improvements for organizations

• “Kaizen” or “continuous improvement” should be a part of our everyday life

• Good is never good enough , kaizen is never- ending journey to excellence

• It helps to turn problems into profit