n

io
rs
ve
Kaizen Management
al
tri
ne
hi
ac
fM
pd

Continuous improvement
 What is Industry ?

n
io
rs
ve
al
tri
ne
hi
ac

Man-power Products
fM

Machines
pd

Services
Materials
Methods
(4M’s, 1E)
pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
 What are evaluation

n
criteria for the output ?

io
rs
ve
al
tri
ne
hi
ac
fM
pd

1
 KAIZEN is a feedback.

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

KAIZEN is a corrective
action.
 KAIZEN is a Japanese word

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd
 Definitions of KAIZEN

n
io
rs
A selection of better means
ve
or a change of current
al
tri

method for achieving an

ne
hi
ac

objective.
fM
pd

An accumulation of small
changes
The way of packing oranges
in Japan

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd
Orange Packing (1)
It is difficult to open a net and put

n
oranges in the net at the same time.

io
rs
ve
al
tri
ne
hi

I need
ac

help.
fM
pd

Productivity: 1 net per min.

Orange Packing (2)
Cooperation increases a work efficiency.

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

Productivity: 5 nets per min.

 A selection of better means or a
change of current method for

n
achieving an objective.

io
rs
ve
al
tri
Can you think of a better
ne
hi

method to pack oranges?

ac
fM
pd

Productivity: 10 nets per min.

1
 When a waitress served a glass of water,
she placed the glass strongly on the table.

n
Hold the glass with care.

io
rs
Place the glass with care.

ve
Treat customers from your heart.
al Change the way of
tri
holding the glass
ne
hi

Hold the bottom of the glass.

ac

Support the glass with a little finger.

fM

Touch the little finger to the table.

pd

2
 Do not give customers
uncomfortable feelings!

n
io
rs
ve
When you hang up the telephone, put it
al
smoothly with an appreciation to the
tri
ne

customer.
hi
ac

Since the customer pays your salary,

fM
pd

hang up your telephone receiver politely.

You must teach a way of accomplishing
the job.
pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
Telephone
 KAIZEN

n
io
rs
ve
al
- Quality Control Circles - Cooperative Labor-
tri
Management relationship
ne

- Suggestion System - Small-group activities

hi

- Just-in-time
ac

- Productivity Improvement
fM

- TQC (Total Quality Control) - Quality Improvement

pd

- Total Productive - New product development

maintenance - Zero Defect (ZD)
- 5 S Kaizen

The Kaizen Umbrella

 When a waitress served a glass of water,
she placed the glass strongly on the table.

n
Hold the glass with care.

io
rs
Place the glass with care.

ve
Treat customers from your heart.
al Change the way of
tri
holding the glass
ne
hi

Hold the bottom of the glass.

ac

Support the glass with a little finger.

fM

Touch the little finger to the table.

pd

2
 KAIZEN Steps
- Abolition
- Discontinuance

n
- Exclusion

io
rs
- Removal

ve
al - Simplification
tri
- Centralization
ne

- Synchronization
- Standardization
hi
ac

- Management for exceptions

- Integration
fM

- Combination
pd

- Alternation
- Exchange
- Conversion
- Diversification
- Separation
4
 Elimination Remove this
sliding door

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

What is the use of the sliding

doors?
 KAIZEN by “Elimination”

n
Why are shoes box doors needed?

io
rs
ve
al
tri
ne
hi
ac
fM
pd

Before After
1
 KAIZEN by “Elimination”
No sleeves down-jacket is easy to work.

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

Before

1
After
 Reduce A fluorescent light
bulb was removed.

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

The number of fluorescent light

were reduced.
 KAIZEN by “Reduction”

n
io
Are two bricks needed

rs
ve
al
tri to stop a car?
ne
hi
ac
fM
pd

Before
pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
Parking Lot
 KAIZEN by “Reduction”

n
io
One brick is enough

rs
ve
to stop a car.
al
tri
ne
hi
ac
fM
pd

Before

After 1
 pd
fM
ac
hi
ne
tri
al
ve
rs
io
n
Zebra Zone

1
 KAIZEN by “Reduction”

n
io
Side lines of

rs
ve
the zebra zone
al
are removed.
tri
ne
hi

Before
ac
fM
pd

After
1
 KAIZEN by “Reduction”
A brush part of the toothbrush is

n
io
rs
not necessarily long.
ve
al
tri
ne
hi
ac
fM
pd

Before After
1
 Change

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

By watching the ribbon movement,

one can recognize that the air
conditioner is working.
 KAIZEN by “Change”

n
io
The hollow about the key hole

rs
ve
smoothes the key movement.
al
tri
ne
hi
ac
fM
pd

Before After
1
 KAIZEN by “Change”

n
io
To oil the pan, a small teapot is

rs
ve
more convenient than a ladle.
al
tri
ne
hi
ac
fM
pd

Before After
1
 KAIZEN by “Change”

n
Stairways at the railway station

io
rs
ve
should have signs of up and down.
al
tri
ne
hi
ac
fM
pd

Before After
1
 pd
fM
ac
hi
ne
tri
al
ve
rs
io
n

At JR Kurume Station
 pd
fM
ac
hi
ne
tri
al
ve
rs
io
n

Rush Hour
 KAIZEN by “Change”

n
The shape of the handing strap

io
rs
fits the hand.
ve
al
tri
ne
hi
ac
fM
pd

Before After 1
 Hanging Straps

n
in trains

io
rs
ve
al
tri
ne
hi
ac
fM
pd
 Hanging strap in
Hong Kong
subways

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

to Suggestion System
Contents
 Objective: Read the gauge to
keep the liquid level constant.

n
io
rs
ve
al
tri
ne
hi
ac
fM
pd

Exercise (1)
 pd
fM
ac
hi
ne
tri
al

Exercise (2)
ve
rs
io
n
 pd
fM
ac
hi
ne

Exercise (3)
tri
al
ve
rs
io
n
 pd
fM
ac
hi
ne
tri
al

Exercise (4)
ve
rs
io
n
 pd
fM
ac
hi
ne
tri
al

Exercise (5)
ve
rs
io
n
 pd
fM
ac
hi

Exercise (6)
ne
tri
al
ve
rs
io
n
 pd
fM
ac
hi
ne
tri
al

Exercise (7)
ve
rs
io
n
 Suggestion System

n
You suggest your ideas, and I will

io
rs
examine them and implement some

ve
of your ideas later.
al
tri
ne
hi
ac
fM
pd
 pd
fM
ac
hi
ne
tri
al
ve
Reward rs
io
n
Idea
Concept

Idea
Suggestion System
 KAIZEN System

n
io
Implemented ideas must be submitted

rs
ve
al
tri
ne
hi
ac
fM

N
IZE
pd

A
K eet
sh
 Suggestion System

n
io
Workers’

rs
ve
responsibility Management responsibility
al
tri
ne
hi
ac
fM

Workers’ responsibility Management

pd

responsibility

KAIZEN System
Difference (1)
 Suggestion system

n
io
Propose improvement ideas for

rs
ve
any activity in the company.
al
tri
ne
hi

KAIZEN system
ac
fM
pd

Propose only improvement ideas

which will improve your own work.

Difference (2)
 pd
fM

Memo
KAIZEN
ac
hi
ne
tri
al
ve
rs
io
n

1
pd
fM
ac
hi
ne
KAIZEN

tri
AOTS Kaizen

al
ve
rs
io
n
pd
fM
ac
hi
ne
tri
AOTS KAIZEN

al
ve
rs
io
n
 Different styles of change

n
io
rs
1. Small change --- By individual effort, a better
ve
way of proceeding a job is
(KAIZEN) al considered. (Idea creation)
tri
ne

2. Medium change --- By group effort, a better way

hi
ac

is proposed by following
(Small group
fM

predetermined steps (or rule).

pd

activities)
3. Big change --- By investments in new technology
or equipment, dramatic alterations
(Innovation) are achieved.
2