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All the employees are involved in taking Kaizen Shapath
Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Employees
Director to Doorman - all are equally involved in doing Kaizen at GEMBA
Preventive Maintenance through Visual Management
Transparent
 containers




Visual Management – Pigments stored in all the containers are visible and known
Through color coding, it is easy to know which tools and components belong to which dept.
Token




               PEEP (Place For Everything and Everything in its Place)
When the person has taken a tool, he will place a token at the place that will let others
know where the tool is now and with whom
Color
                      coding


                                   Standard
                                     WIP




                  Output



Input



  1. Frontline workers are cleaning their workstations to keep their workplace dust-free
  2. Standard WIP has been kept near every workstation
  3. All the components have been color coded according to their functionality and
     stored at the point of use (POU)
Light indicator
                                                                   to give signal
 Plan vs. Actual
   production
 display board                                      Material at
                                                      hands
                                                     distance




            Packaging




This is an example of One Piece Flow Assembly
Each and every component needed is available at a hands distance of the worker
Worn out/Waste
                                                    tools are kept in
                                                        one line




Learning Center - where all kinds of tools are kept to train the employees
SMED
                                               trolley




All the tools required (related to the machine) to perform the changeover are available in
SMED trolley. Big stand is available in the left corner where all the tools are kept that will
be needed during changeover, it helps to avoid Muda of Motion & Transportation
Responsibility has
                                                                          been assigned to
                                                                             Shift Fitter




SMED trolley contains all the tools required to perform quick changeover. SMED trolley
has been parked only in the right area
• Place for everything and every useful thing in its place (PEEP)
• Kanban system
• No stock out or over-stocking of material
Kanban
Collection
   tray




Once any material has been picked up for use, the Kanban card of the particular material
will go into the Kanban collection tray. It will then be sent to purchase department at
every 11 am & 4 pm daily for placing the replenishment orders
Light
                                                                                  signal



                   Mizusumashi
                  (Water Spider)




Whenever the operators need some material, they trigger the light that gives signal to
Mizusumashi (Water Spider) who replenishes the required material in the workstation
Responsibility
                                assigned




Kanban
 Card

                                                   Kanban
                                                    Board




         Point of Use Storage (POUS) with Kanban
Name of the
         Oil stored


Count
 Free




             Same color
             marking is
              done on
                M/C




              No Oil Drops
              on the Floor



        Visual Management
Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer
Kaizen For kids (KFK)
Yogesh Vaghani discussing the importance of Kaizen with School Faculty

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Kaizen Examples

  • 1. All the employees are involved in taking Kaizen Shapath
  • 2. Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Employees
  • 3. Director to Doorman - all are equally involved in doing Kaizen at GEMBA
  • 4. Preventive Maintenance through Visual Management
  • 5. Transparent containers Visual Management – Pigments stored in all the containers are visible and known
  • 6. Through color coding, it is easy to know which tools and components belong to which dept.
  • 7. Token PEEP (Place For Everything and Everything in its Place) When the person has taken a tool, he will place a token at the place that will let others know where the tool is now and with whom
  • 8. Color coding Standard WIP Output Input 1. Frontline workers are cleaning their workstations to keep their workplace dust-free 2. Standard WIP has been kept near every workstation 3. All the components have been color coded according to their functionality and stored at the point of use (POU)
  • 9. Light indicator to give signal Plan vs. Actual production display board Material at hands distance Packaging This is an example of One Piece Flow Assembly Each and every component needed is available at a hands distance of the worker
  • 10. Worn out/Waste tools are kept in one line Learning Center - where all kinds of tools are kept to train the employees
  • 11. SMED trolley All the tools required (related to the machine) to perform the changeover are available in SMED trolley. Big stand is available in the left corner where all the tools are kept that will be needed during changeover, it helps to avoid Muda of Motion & Transportation
  • 12. Responsibility has been assigned to Shift Fitter SMED trolley contains all the tools required to perform quick changeover. SMED trolley has been parked only in the right area
  • 13. • Place for everything and every useful thing in its place (PEEP) • Kanban system • No stock out or over-stocking of material
  • 14. Kanban Collection tray Once any material has been picked up for use, the Kanban card of the particular material will go into the Kanban collection tray. It will then be sent to purchase department at every 11 am & 4 pm daily for placing the replenishment orders
  • 15. Light signal Mizusumashi (Water Spider) Whenever the operators need some material, they trigger the light that gives signal to Mizusumashi (Water Spider) who replenishes the required material in the workstation
  • 16. Responsibility assigned Kanban Card Kanban Board Point of Use Storage (POUS) with Kanban
  • 17. Name of the Oil stored Count Free Same color marking is done on M/C No Oil Drops on the Floor Visual Management
  • 18. Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer
  • 20. Yogesh Vaghani discussing the importance of Kaizen with School Faculty