Kaizen training

S
Sukin ShettyProcess Engineer um TOKAI RIKA MINDA PVT LTD
TRAINING ON
            KAIZEN
                                            SUKIN.S.SHETTY

KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD        1
TOPICS TO BE DISCUSSED
   INTRODUCTION OF KAIZEN
   7 TYPES OF WASTES
   WHY KAIZEN
   8 KEY ELEMENTS OF KAIZEN CULTURE
   KAIZEN MINDSET
   TOYOTA PRODUCTION SYSTEM
   BENEFITS OF KAIZEN
   HOW TO IMPLEMENT KAIZEN

KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   2
INTRODUCTION
  KAIZEN MEANS CONTINUOUS IMPROVEMENT
  IN JAPAN :




 KAIZEN                                    CHANGE FOR BETTER
 KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD         3
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   4
TPS created KAIZEN based on DEMINGS cycle or PDSA cycle




KAIZEN TRAINING         TOKAI RIKA MINDA INDIA PVT LTD         5
MAKE EVRYTHING AS SIMPLE AS
POSSIBLE BUT NOT SIMPLER


                          -- ALBERT EINSTIEN


KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   6
KAIZEN is a system of continuous improvement in
quality, technology, process, company culture,
productivity, safety and leadership.


KAIZEN was developed in 1950 after the world war-II
by TAIICHI OHNO and SHIGEO SHINGO based on
DEMINGS CYCLE or SHEWART CYCLE or PSDA
CYCLE.
 KAIZEN involves setting standards and then
 continuously improving those standards




KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD      7
DEMINGS CYCLE




 KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   8
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   9
DEMINGS CYCLE

  DEMINGS CYCLE or SHEWART CYCLE or PSDA
  CYCLE found by EDWARDS DEMINGS AND WALTER
  SHEWART
      It is a continuous quantity improvement model
      consisting of a logical sequence of four repetition
      steps for continuous improvement and learning

 PLAN              PLAN AHEAD FOR CHANGE. ANALYSE & PREDICT
                   RESULTS
 DO                EXCUTE THE PLAN TAKING SMALL STEPS.
 STUDY             CHECK AND STUDY THE RESULTS
 ACT               TAKE ACTION TO STANDARDIZE
 KAIZEN TRAINING       TOKAI RIKA MINDA INDIA PVT LTD         10
KAIZEN CYCLE
      START         IDENTIFY WASTE
      HERE                                           CELEBRATE




  PLAN COUNTER
  MEASURES                                            MAKE
                                                      STANDARD




REALITY CHECK
                                                     VERIFY

                        MAKE CHANGES



  KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD            11
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   12
7 types of wastes




  KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   13
7 types of wastes               waste                  MUDA

1. Over production -- Production more than required.
2. WAITING – Process delays idle time.
3. TRANSPORTATION – Delay in material handling.
4. EXCESS INVENTORY – Excess of raw material & tools for
   production.
5. Motion – Actions of people or equipment that do not add value.
6. OVER PROCESSING – Unnecessary stops or work elements or
   procedures.
7. DEFECTIVE UNITS – Production of a part that is scrapped or
   require work.



KAIZEN TRAINING       TOKAI RIKA MINDA INDIA PVT LTD            14
The foundation of Kaizen method consists of 5
  founding methods :
1. Team work
2. Personal discipline
3. Improved Morale
4. Quality circles
5. Suggestions for improvement.




KAIZEN TRAINING      TOKAI RIKA MINDA INDIA PVT LTD   15
Improved Morale :




Quality circles : Employee participation program.
                 It consists of employees who meet
periodically to identify strength and weakness in
production




KAIZEN TRAINING     TOKAI RIKA MINDA INDIA PVT LTD   16
WHY KAIZEN
 1. To eliminate waste in organization.
 2. To increase productivity.
 3. To improve quality
 4. Customer satisfaction.
 5. Growth of the organization.
 6. To eliminate any abnormalities & stopping of limits
 7. Developing self personality.




 KAIZEN TRAINING     TOKAI RIKA MINDA INDIA PVT LTD       17
8 KEY ELEMENTS OF KAIZEN CULTURE
 1. KAIZEN MINDSET
 2. CUSTOMER ORIENTATION
 3. QUALITY CONTROL CIRCLES
 4. SUGGESTION SYSTEM
 5. DISCIPLINE IN WORKPLACE
 6. SMALL GROUP ACTIVITIES
 7. CO-OPERATIVE RELATIONS
 8. TOTAL QUALITY MANGEMENT.



 KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   18
KAIZENMINDSET
 1. EVERYTHING CAN & SHOULD BE IMPROVED
 2. NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF
    IMPROVEMENT.
 3. IMAGINE THE IDEAL CUSTOMER EXPERIENCE AND STRIVE TO
    PROVIDE IT.
 4. DON’T JUST CRITICIZE,SUGGEST AN IMPROVEMENT.
 5. THINK OF HOW TO IMPROVE IT INSTEAD OF WHY IT CANT.
 6. SET TARGET AND MOTIVATE YOURSELF TO ACHIVE IT.
 7. USE COMPTETION TO AROUSE INTEREST.
 8. DON’T LOOK FOR REWARDS.
 9. GENERATE MORE QUESTIONS.

 10. SAY YOURSELF I   CAN DO IT


 KAIZEN TRAINING         TOKAI RIKA MINDA INDIA PVT LTD   19
TOYOTA PRODUCTION SYSTEM- TPS
TAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 1975.


They visited several FORD motor company automotive plants in Michigan.
  But observed some methods not very effective . Then by chance they
  visited supermarket Piggly Wiggly. They were inspired how the products
  were re ordered and restocked goods. Reducing inventory by using just in
  time ( JIT) inventory system. Using easy methods to display their goods
  and arranging manpower only wherever required. They were doing good
  business with less investment.
Main objective of TPS was :
1. Reduce inventory by following JIT.
2. Standardised work management.
3. Continuous improvement.
4. Lean manufacturing
5. Customer satisfaction
  KAIZEN TRAINING             TOKAI RIKA MINDA INDIA PVT LTD           20
KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN AND
WEST
          WEST                                           JAPAN
 1. Deals with quality of                1. Deals with quality of
    products.                               products

 2. Manufacturer oriented                2. Customer oriented.

 3. Product oriented aimed at            3. Process oriented aimed at
    detecting and eliminating               improving the total
    defected parts.                         performance.

 4. Responsibility of quality            4. Company wide, everybody
    control managers.                       is responsible.




  KAIZEN TRAINING       TOKAI RIKA MINDA INDIA PVT LTD              21
BENEFITS OF KAIZEN
1. Savings in energy, material & others resources.
2. Improvements in working environment.
3. Improvements in machines & process.
4. Improvements in jigs & tools.
5. Capable of generating new ideas.
6. Customer satisfaction.
7. Elimination of wastes.
8. Improvement in product quality.
9. Improvement in 5S.
10.Improvement in self personality.
11.Improvements in own work..

   KAIZEN TRAINING          TOKAI RIKA MINDA INDIA PVT LTD   22
HOW TO IMPLEMENT KAIZEN

            Employee identifies problem, waste or
            an opportunity for improvement and
            write it down




             The employee develops an improvement
             idea & discuss with his or her
             supervisor




 KAIZEN TRAINING       TOKAI RIKA MINDA INDIA PVT LTD   23
The supervisor reviews the idea within
            24hrs & encourages immediate action.




             The employee implements the idea




                  The idea is written upon a simple Kaizen
                  sheet




KAIZEN TRAINING            TOKAI RIKA MINDA INDIA PVT LTD    24
Supervisor publishes the Kaizen and rewards
      will be given

        CELEBRATE THE SUCCESS OF YOUR KAIZEN




KAIZEN TRAINING     TOKAI RIKA MINDA INDIA PVT LTD   25
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   26
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   27
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   28
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   29
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   30
KAIZEN TRAINING   TOKAI RIKA MINDA INDIA PVT LTD   31
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Kaizen training

  • 1. TRAINING ON KAIZEN SUKIN.S.SHETTY KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 1
  • 2. TOPICS TO BE DISCUSSED  INTRODUCTION OF KAIZEN  7 TYPES OF WASTES  WHY KAIZEN  8 KEY ELEMENTS OF KAIZEN CULTURE  KAIZEN MINDSET  TOYOTA PRODUCTION SYSTEM  BENEFITS OF KAIZEN  HOW TO IMPLEMENT KAIZEN KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 2
  • 3. INTRODUCTION KAIZEN MEANS CONTINUOUS IMPROVEMENT IN JAPAN : KAIZEN CHANGE FOR BETTER KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 3
  • 4. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 4
  • 5. TPS created KAIZEN based on DEMINGS cycle or PDSA cycle KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 5
  • 6. MAKE EVRYTHING AS SIMPLE AS POSSIBLE BUT NOT SIMPLER -- ALBERT EINSTIEN KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 6
  • 7. KAIZEN is a system of continuous improvement in quality, technology, process, company culture, productivity, safety and leadership. KAIZEN was developed in 1950 after the world war-II by TAIICHI OHNO and SHIGEO SHINGO based on DEMINGS CYCLE or SHEWART CYCLE or PSDA CYCLE. KAIZEN involves setting standards and then continuously improving those standards KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 7
  • 8. DEMINGS CYCLE KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 8
  • 9. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 9
  • 10. DEMINGS CYCLE DEMINGS CYCLE or SHEWART CYCLE or PSDA CYCLE found by EDWARDS DEMINGS AND WALTER SHEWART It is a continuous quantity improvement model consisting of a logical sequence of four repetition steps for continuous improvement and learning PLAN PLAN AHEAD FOR CHANGE. ANALYSE & PREDICT RESULTS DO EXCUTE THE PLAN TAKING SMALL STEPS. STUDY CHECK AND STUDY THE RESULTS ACT TAKE ACTION TO STANDARDIZE KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 10
  • 11. KAIZEN CYCLE START IDENTIFY WASTE HERE CELEBRATE PLAN COUNTER MEASURES MAKE STANDARD REALITY CHECK VERIFY MAKE CHANGES KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 11
  • 12. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 12
  • 13. 7 types of wastes KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 13
  • 14. 7 types of wastes waste MUDA 1. Over production -- Production more than required. 2. WAITING – Process delays idle time. 3. TRANSPORTATION – Delay in material handling. 4. EXCESS INVENTORY – Excess of raw material & tools for production. 5. Motion – Actions of people or equipment that do not add value. 6. OVER PROCESSING – Unnecessary stops or work elements or procedures. 7. DEFECTIVE UNITS – Production of a part that is scrapped or require work. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 14
  • 15. The foundation of Kaizen method consists of 5 founding methods : 1. Team work 2. Personal discipline 3. Improved Morale 4. Quality circles 5. Suggestions for improvement. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 15
  • 16. Improved Morale : Quality circles : Employee participation program. It consists of employees who meet periodically to identify strength and weakness in production KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 16
  • 17. WHY KAIZEN 1. To eliminate waste in organization. 2. To increase productivity. 3. To improve quality 4. Customer satisfaction. 5. Growth of the organization. 6. To eliminate any abnormalities & stopping of limits 7. Developing self personality. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 17
  • 18. 8 KEY ELEMENTS OF KAIZEN CULTURE 1. KAIZEN MINDSET 2. CUSTOMER ORIENTATION 3. QUALITY CONTROL CIRCLES 4. SUGGESTION SYSTEM 5. DISCIPLINE IN WORKPLACE 6. SMALL GROUP ACTIVITIES 7. CO-OPERATIVE RELATIONS 8. TOTAL QUALITY MANGEMENT. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 18
  • 19. KAIZENMINDSET 1. EVERYTHING CAN & SHOULD BE IMPROVED 2. NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF IMPROVEMENT. 3. IMAGINE THE IDEAL CUSTOMER EXPERIENCE AND STRIVE TO PROVIDE IT. 4. DON’T JUST CRITICIZE,SUGGEST AN IMPROVEMENT. 5. THINK OF HOW TO IMPROVE IT INSTEAD OF WHY IT CANT. 6. SET TARGET AND MOTIVATE YOURSELF TO ACHIVE IT. 7. USE COMPTETION TO AROUSE INTEREST. 8. DON’T LOOK FOR REWARDS. 9. GENERATE MORE QUESTIONS. 10. SAY YOURSELF I CAN DO IT KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 19
  • 20. TOYOTA PRODUCTION SYSTEM- TPS TAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 1975. They visited several FORD motor company automotive plants in Michigan. But observed some methods not very effective . Then by chance they visited supermarket Piggly Wiggly. They were inspired how the products were re ordered and restocked goods. Reducing inventory by using just in time ( JIT) inventory system. Using easy methods to display their goods and arranging manpower only wherever required. They were doing good business with less investment. Main objective of TPS was : 1. Reduce inventory by following JIT. 2. Standardised work management. 3. Continuous improvement. 4. Lean manufacturing 5. Customer satisfaction KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 20
  • 21. KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN AND WEST WEST JAPAN 1. Deals with quality of 1. Deals with quality of products. products 2. Manufacturer oriented 2. Customer oriented. 3. Product oriented aimed at 3. Process oriented aimed at detecting and eliminating improving the total defected parts. performance. 4. Responsibility of quality 4. Company wide, everybody control managers. is responsible. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 21
  • 22. BENEFITS OF KAIZEN 1. Savings in energy, material & others resources. 2. Improvements in working environment. 3. Improvements in machines & process. 4. Improvements in jigs & tools. 5. Capable of generating new ideas. 6. Customer satisfaction. 7. Elimination of wastes. 8. Improvement in product quality. 9. Improvement in 5S. 10.Improvement in self personality. 11.Improvements in own work.. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 22
  • 23. HOW TO IMPLEMENT KAIZEN Employee identifies problem, waste or an opportunity for improvement and write it down The employee develops an improvement idea & discuss with his or her supervisor KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 23
  • 24. The supervisor reviews the idea within 24hrs & encourages immediate action. The employee implements the idea The idea is written upon a simple Kaizen sheet KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 24
  • 25. Supervisor publishes the Kaizen and rewards will be given CELEBRATE THE SUCCESS OF YOUR KAIZEN KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 25
  • 26. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 26
  • 27. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 27
  • 28. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 28
  • 29. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 29
  • 30. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 30
  • 31. KAIZEN TRAINING TOKAI RIKA MINDA INDIA PVT LTD 31