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Kaizen

Kai Change
Zen For the
better
Kaizen Change for the better refers to
activities that continually improve all functions and involve
all employees
Basic Goals
Discover and Eliminate all Waste in a process
Waste anything that the customer does not pay for
Some waste is necessary or required by law (personnel
files, financial records, meetings, etc.)

Kaizen
Types of Waste

Overproduction
Waiting
Overprocessing
Inventory
Motion
Defects
Transportation

Kaizen
Traditional Market scenario

Cost + Profit =
Selling price

Current Market scenario

Selling price - Cost =


Profit
Kaizen Event
Focused effort by a full-time, cross-functional team to analyze and
improve a process in a short time (usually 1 week)

Kaizen
Kaizen Tools

Flowcharts

Cause and Effect


Diagrams

Value Stream
Mapping

5S

Pareto Charts

Histograms

Takt and Cycle


times

Control charts

Poka Yoke

Scatter Plots

Kanban

Check Sheets

Visual Controls

Statistical Methods

Preventive
Maintenance

5 Whys

Kaizen
VSM (Value Stream Mapping)
Special type of flow chart that uses symbols
known as
"the Language of Lean" to depict and
improve the flow

Provide optimum value to the customer through a complete


value creation process with minimum waste in:
Design (concept to customer)
Build (order to delivery)
Sustain (in-use through life cycle to service)

Kaizen
VSM (Example)

Kaizen
5S

Kaizen
5S

Kaizen
5 Whys

Kaizen
How to use the Kaizen Tools

Kaizen
Practical keys to Kaizen Success

Standardize your work


easier and safer
Solve problems together
Eliminate waste ask why 5
times
Make everything visual
understanding at a glance
Offer your ideas