• A STRATEGY FOR PERFORMANCE

EXCELLENCE

TPM Secretariat ,Vasai

 What Does Kaizen Mean?

• KAI ZEN
• To modify, to change Think, make good, make better

• = KAIZEN
• Make it easier by studying it, and making the improvement
through elimination of Loss/waste.

TPM Secretariat ,Vasai

 Objectives of Kaizen

Fill the difference between present status

and target

• First, bring to a condition of the past,

another line or another company
• Copying is also technology
• Develop new ideas by changing conception
• Importance is to train people who can maintain

TPM Secretariat ,Vasai

 Types of Kaizen

•Restorative Kaizen – To achieve good condition in the

past

- Aim at good condition in the

. past.

Restorative Past Level

Difference Present Level

TPM Secretariat ,Vasai

 Types of Kaizen

•Renovative Kaizen – To achieve Optimum condition in

the past

-Aim at achieving “what the equipment

and the operation must be” in the future.
Renovating
Future Level

Difference Present Level

TPM Secretariat ,Vasai

 Kaizen Training
Basic Rules for Change
Keep an open mind to change
No such thing as a dumb question or idea

Avoid spending money (Capital expense should

be a last resort)
Maintain a positive attitude

Don’t’ make excuses & question current practices

Think about how to do it, NOT why it can’t be done

Just do it!!
Have Fun!!!
TPM Secretariat ,Vasai
TPM Secretariat ,Vasai
 KAIZEN IDEA SHEET Kaizen No KZ09/0000062
Machine: Activity KK JH QM PM SHE OTPM DM ET
1.Kaizen theme: Loss No./Step No VASAI
Result area P Q C D S M
Team members:
2.Benchmark: 10.Idea : This Kaizen is :
3.Target: Providing 9 Changing
4.Kaizen Start:
5.Kaizen Finished: 9 Reversible Irreversible
6.Problem present status: (in words) 11.Countermeasure: 14. Cost of this Kaizen:

15.Benefits:

7. (Illustration with sketch) 12. (Illustration with sketch)

8.Analysis:(Why-Why analysis) 13. Result: 16.How to sustain:

1.Why ?

2.Why ?

17.Scope & Plan for Horizontal Deployment

Sr. Target
M/C No. Responsibility
No. date

9.Root cause:

TPM Secretariat ,Vasai

 Different Terms used in Kaizen sheet
• (1)Kaizen Theme • (10)Idea
• (2)Benchmark • (11)Countermeasure
• (3)Target • (12)Illustrate with
Sketch(After)
• (4)Kaizen Start
• (13)Results
• (5)Kaizen Finish
• (14)Cost Of this
• (6)Problem Present Status
Kaizen
• (7)Illustrate with Sketch(Before)
• (15)Benefits
• (8)Analysis
• (16)How to Sustain?
• (9)Root Cause
• (17)Scope and Plan
for Horizontal
Deployment
TPM Secretariat ,Vasai
 Different Terms used in Kaizen sheet

• Kaizen No
• Machine
• Activity ( Which Pillar)
• Loss No/Step No
• Result Area
• Team Members
• Providing/Changing
• Reversible/Irreversible

TPM Secretariat ,Vasai

Kaizen Theme(1) --- It is a theme which states about the purpose
of the kaizen for which it is implemented

Bench Mark(2) --- It is a base line figure taken at the

point of analysis or kaizen planned.In short ,it is a
present level
Target(3) --- It is a past or future level which we want
to achieve by implementation of Kaizen
Kaizen Start(4) --- It is a date on which implementation
of Kaizen started

Kaizen Finish(5) --- It is a date on which implementation

of Kaizen Completed

TPM Secretariat ,Vasai

Problem Present Status(6) --- It is a statement which says about
the current situation of the problem.

Illustrate with Sketch(Before)(7) --- It can be a sketch or

photo showing present problem status

Analysis(8) --- Root cause analysis (RCA) is a sequential

and investigative process used to determine the root
cause of the problem
Root Cause(9) --- It is the factor that caused
breakdown,defect,accident or nonconformance

TPM Secretariat ,Vasai

Idea(10) --- It is an imaginary action planned opposite
to root cause to achieve target.

Countermeasure(11) --- It is an action which is /can be

physically implemented to achieve past/future level which we
want to achieve by implementation of Kaizen

Illustrate with Sketch(After)(12) --- It can be a sketch or

photo showing status after implementation of Kaizen.

Results(13) --- It is a graphical representation showing

relation or status between Benchmark & Target of
intended theme of kaizen

TPM Secretariat ,Vasai

Cost of Kaizen(14) --- This is the expenditure
incurred for implementing Improvement theme. It
includes spares as well as labour cost.
Benefits(15) --- Benefits should be in terms of
PQCDSM. Benefits achieved as shown in results area
should not be repeated here.
How to Sustain(16) ---The activity to be carried
out to sustain the results and benefits shown in
kaizen is required to mention here.

Scope and plan for horizontal deployment(17) --- It

says about whether Same kaizen can be deployed on
other machines,processes of same nature and action
plan for that.

TPM Secretariat ,Vasai

Kaizen no --- It is a serial number for controlling kaizen
document

Machine --- Name/code of the machine on which kaizen to

be implemented

Activity --- Here all 8 pillars are stated in different cell.

Highlight the pillar to which kaizen theme is related

Loss No /Step No --- It is a loss/step no from where the

kaizen is initiated

TPM Secretariat ,Vasai

Result Area --- Highlight either of PQCDSM in line with
intended motive of kaizen

Team Members --- Those who are involved in identification

and implementation of Kaizen

Providing/Changing --- Providing can be restorative type of

Kaizen and Changing can be Rennovative type of Kaizen

Reversible/Irreversible --- This section gives us a flag that if

it is irreversible , carry out FMEA before implementation of
kaizen

TPM Secretariat ,Vasai

 KAIZEN IDEA SHEET Kaizen No KZ09/0000062
Machine: Activity KK JH QM PM SHE OTPM DM ET
1.Kaizen theme: Loss No./Step No VASAI
Result area P Q C D S M
Team members:
2.Benchmark: 10.Idea : This Kaizen is :
3.Target: Providing 9 Changing
4.Kaizen Start:
5.Kaizen Finished: 9 Reversible Irreversible
6.Problem present status: (in words) 11.Countermeasure: 14. Cost of this Kaizen:

15.Benefits:

7. (Illustration with sketch) 12. (Illustration with sketch)

DO
ACT

8.Analysis:(Why-Why analysis) 13. Result: 16.How to sustain:

1.Why ?

2.Why ?
CHECK
PLAN
17.Scope & Plan for Horizontal Deployment
Sr. Target
M/C No. Responsibility
No. date

9.Root cause:

TPM Secretariat ,Vasai

 KAIZEN IDEA SHEET Kaizen No KZ09/0000062
Machine: Activity KK JH QM PM SHE OTPM DM ET
1.Kaizen theme: Loss No./Step No VASAI
Result area P Q C D S M
Team members:
2.Benchmark: 10.Idea : This Kaizen is :
3.Target: Providing 9 Changing
4.Kaizen Start:
5.Kaizen Finished: 9 Reversible Irreversible
6.Problem present status: (in words) 11.Countermeasure: 14. Cost of this Kaizen:

15.Benefits:

7. (Illustration with sketch) 12. (Illustration with sketch)

8.Analysis:(Why-Why analysis) 13. Result: 16.How to sustain:

1.Why ?

2.Why ?

17.Scope & Plan for Horizontal Deployment

Sr. Target
M/C No. Responsibility
No. date

9.Root cause:

TPM Secretariat ,Vasai

TPM Secretariat ,Vasai