Kaizen ppt

1. Kaizen In Manufacturing
Industry

2. Outline
 What is kaizen?
 Nature of kaizen
 5s framework of kaizen
 The cycle of kaizen activity
 Case study on Elin Company
 Swot analysis
 Conclusion
 Recommendations

3. What is kaizen?
 From the Japanese words “kai” which means “change” and “Zen” which means “good.”
 Kaizen (Continuous Improvement) is a strategy where employees at all levels of a company
work together proactively to achieve regular, incremental improvements to the
manufacturing process.
 In a sense, it combines the collective talents within a company to create a powerful engine
for improvement.

4. Dual Nature Of Kaizen
Kaizen is part action plan and part philosophy. Consistent application of Kaizen as an
action plan develops Kaizen as a philosophy

5.  5S is the foundation
of all
improvements and
is the key
component of
establishing a Visual
Workplace. Both are
a part of Kaizen a
system of continual
improvement which
is a component of
lean manufacturing.

6. The Cycle Of kaizen Activity
 Plan- ahead for change. Analyze the and
predict the results
 Do- execute the plan taking small steps in
controlled circumstances
 Check- study the results means comparing
actual results against the expected results
 Action- Take action to standardize or
improve the process

7. Practical Study on
Elin Company
 Elin has manufacturing facilities at
Ghaziabad, near New Delhi, The
company has been constantly
delighting its customers with
competitive products by focusing on
continuous improvements in its
systems & processes. Apart from JMG
(Juicer Mixer Grinder),Dry and Stream
Irons, Hair Dryers, Flash Lights and
VISI cooler.

8. Case Study On Elin Company
 The assembly line consist of 34 operations and 39 operators working collectively to make a VISI
cooler. It is observed that there is imbalance in the assembly line. Some operation consumes
more time then the Takt time for each processes.
 Takt time calculation before Kaizen
Takt time = Net available time per shift/no of pieces= 420/600=0.7 minute= 42 seconds
 This Takt time is calculate by considering all processes and parameters standardized. This
includes no waste and no human fatigue. Here machine fault time, material delay, defected
pieces and other non value added activities are not calculated

9. 23
28
20
46
35
42 40
56
52
37
69
55 54 53
68
53
76
29
44
51
20 10 16
250
40
31
24
28
15 18 20 10
30
0
50
100
150
200
250
300
D…
C…
V…
I…
B…
C…
T…
D…
T…
S…
G…
E…
C…
T…
W…
P…
W…
A…
A…
V…
S…
D…
S…
T…
O…
I…
FI…
T…
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Load chart of operators before kaizen

10. Implementation Of Kaizen In Elin
Company (A Cooler Industry)
 Kaizen helped to reduce the unnecessary movements. Some operations were combined with
each others
 Operation “Temperature Testing” involved 250 seconds which is really high and overcome by
installing 4 new temperature tester. Gasket operation is another time consuming event. The
operator has to fix the gasket and move the job back to nearby operator 1. The operation is
clubbed and it reduced the time.

11. Implementation Of Kaizen In Elin
Company (A Cooler Industry)
 After Kaizen implementation the result is impressive. The number of operators reduced to 33 from 39
and number of operations reduced to 30 from 34.
 Kaizen provided small improvements to assembly line. These small improvements on various stages
adds up to big results. The time saved after Kaizen was significant.
 The total lead time before Kaizen was 1505 seconds while after Kaizen is 1039 seconds. A total saving of
466 seconds. It is well said that for any organization time is money.
 The flow of assembly line is much smoother now and there is reduction in the waiting time for
operators.
 The ultimate achievements of Kaizen implementation was improved productivity, reduced cycle time,
more number of jobs per shift and satisfied customers.

12. Swot Analysis
 Strengths
 Products manufacturing according to customer needs
 Financial strengths stabled
 Kaizen helps to increase productivity
 Weaknesses
 Employees skills need to be upgraded
 Faces heavy competition
 Difficulty to implement the kaizen in existing system

13. Swot Analysis
 Opportunities
 Adapt the latest technologies
 Company has complex assembly of products and able to produce many
 Trends in increasing consumer purchasing power
 Threats
 Higher cost of utilities
 Regulations of Govt & taxes
 Tough competition

14. Conclusion
 Kaizen philosophy if implemented well will produce marvellous result. In this cooler industry
the Kaizen reduced the cycle time for various processes. Kaizen toolbox helped to find the
cause of the extra time taken by the operators. This study is the proof that Kaizen will help
organizations to outperform peers and achieve high performance with optimum use of
resources. Kaizen is a continuous process and needs regular attention. It can be concluded
that if implemented well Kaizen can yield

15. Recommendations
 The kaizen methodology requires training staff and management, so the company should
trained their employees and upgraded their skills.
 Company should maintain a practice of open communication for kaizen to be efficient and
employees should be given the opportunity to give their reviews without any fear