TRAINING ON

KAIZEN
SUKIN.S.SHETTY

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 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

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INTRODUCTION
KAIZEN MEANS CONTINUOUS IMPROVEMENT
IN JAPAN :

KAIZEN CHANGE FOR BETTER

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 TPS created KAIZEN based on DEMINGS cycle or PDSA cycle

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MAKE EVRYTHING AS SIMPLE AS
POSSIBLE BUT NOT SIMPLER

-- ALBERT EINSTIEN

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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

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DEMINGS CYCLE

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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
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 KAIZEN CYCLE
START IDENTIFY WASTE
HERE CELEBRATE

PLAN COUNTER
MEASURES MAKE
STANDARD

REALITY CHECK
VERIFY

MAKE CHANGES

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7 types of wastes

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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.

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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.

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Improved Morale :

Quality circles : Employee participation program.

It consists of employees who meet
periodically to identify strength and weakness in
production

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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.

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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.

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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. DONT 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. DONT LOOK FOR REWARDS.
9. GENERATE MORE QUESTIONS.

10. SAY YOURSELF I CAN DO IT

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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
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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.

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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..

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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

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 The supervisor reviews the idea within
24hrs & encourages immediate action.

The employee implements the idea

The idea is written upon a simple Kaizen

sheet

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 Supervisor publishes the Kaizen and rewards
will be given

CELEBRATE THE SUCCESS OF YOUR KAIZEN

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