KAIZEN

KAIZEN

-Pioneered and brought into US by Masaaki Imai

-It is a philosophy that defines the management role in continuously encouraging and implementing small improvements involving everyone.

-It also means “continuous improvement”

Take small steps

Three Basic Principles of Kaizen

Work Place Effectiveness

Elimination of waste, strain and discrepancy

Standardization

Work Place Effectiveness

1. Seiri (Sort)2. Seiton (Straighten)3. Seiso (Scrub)4. Seikutsu (Systematize)5. Shitsuke (Standardize)

5S Tools

Elimination of waste,

strain and discrepancy

MUs

MUda means WasteMUri means StrainMUra means Discrepancy

7 Deadly Waste 1. Waste from overproduction – occurs due to production

planning when money is blocked in the unsold products. 2. Waste of waiting time – Work- In- Progress is an example

of waste of waiting time. 3. Transportation waste – Unnecessary waste. 4. Processing waste – If a process is held up due to

breakdown of the machinery, money is loss. 5. Inventory waste – every part should be accounted to

avoid inventory waste. 6. Waste of motion – Searching for things, non availability of

the correct tools, not monitoring the running machine                                        etc. can cause wastage of lot of time.

7. Production defects- the defective parts or supplies cause loss of money.

Standardization *  Represent the best, easiest and safest way to do a

job.*  Offer the best way to preserve know-how and expertise*  Provide a way to measure performance*  Show the relationship between cause and effect*  Provide a basis for both maintenance and improvements*  Provide objectives and indicate training goals*  Create a basis for audit or diagnosis*  Provide a means for preventing recurrence of errors and minimizing variability