KAIZEN

A LEAN MANUFACTURING TOOL FOR CONTINUOUS

IMPROVEMENT

Presented by : PPP / MKS (Management Services)

Date : 16-06-2015
  HISTORY :-

 Concept of KAIZEN is evolved in Japan around 1950 & was introduced by Mr.
Taichi Ohno in implementation of world famous Toyota Production System
(TPS).

 The term KAIZEN was made famous to western organizations by Mr. Masaaki
Imai in his famous book, Kaizen: The Key to Japan's Competitive Success
(1986)

KAIZEN
 WHAT IS KAIZEN…???

 Kaizen is a Japanese term which means

"continuous improvement" by doing things
better and setting and achieving increasingly
higher standards.
 Kaizen Literally means “CHANGE FOR
BETTER”
 Kaizen refers to activities that continually
CONTINUOUS
improve all functions.
 Kaizen involve all employees from the CEO

to the assembly line workers.

KAIZEN
 WHAT IS KAIZEN…???

 Kaizen usually delivers small improvements,

the kaizen culture of doing small
improvements yields large results in terms of
overall improvements.
 Kaizen is a method that strives for quality
improvement by identifying and eliminating
waste in the work place, and processes
 Kaizen is nothing but any new idea which can
be implemented so as to achieve better
quality standards, cost savings, inventory
savings, ease of working, safety etc.

KAIZEN
 BENEFITS OF KAIZEN :-

Identification and solving of

problem at source of generation

Can be implemented in manufacturing

as well as non manufacturing areas

Reduces Wastages in process improving

quality, cost saving, time saving etc

Better utilization of machine, man,

BENEFITS space, material etc

OF Shows Immediate results

KAIZEN Easy and low capital
implementations

Builds continuous improvement

culture

KAIZEN
 KAIZEN IMPLEMETATION PROCESS FLOW :-

1 ●
KAIZEN (An improvement idea) is generated by employee

Employee shares KAIZEN with approver, explains advantages, cost involved in implementation, time &
2
●

support required for implementation

Approver evaluates feasibility of KAIZEN, checks if previously done anywhere, may consults others
3
●

regarding same.

4 ●
Decision for approval or rejection is to be taken by approver and same to be inform to KAIZEN owner

5 ●
If KAIZEN is approved, plan for implementation, Take photographs and details of current state.

After implementation check for desired results and record details of improved state with photograph
6
●

wherever possible.

7 ●
Again analyze system for continuous improvement

KAIZEN
 ADMINISTRATION & REWARDS :-
 ROLE OF ADMINISTRATOR :-
 Physically verify every KAIZEN reported.
 Keep record of each KAIZEN reported.

 Keep record of reward points for each KAIZEN owner.

 Frequently check and verify implemented KAIZEN are maintained.

 REWARD SCHEME :-
 Reward scheme will help to grow KAIZEN CULTURE by encouraging and motivating
employees for generating KAIZEN.
 Under reward scheme, 1 point shall be given to each KAIZEN member for each KAIZEN
implemented.
 For every 10,15, 20 etc points a reward shall be given to KAIZEN owners on quarterly
basis.
 3 Best KAIZENS shall be rewarded quarterly with certificate and special reward (like
BBL Bag, BBL Shirts, BBL KAIZEN T-SHIRT etc) along with recognition on BBL
PORTAL
KAIZEN
 ADMINISTRATION & REWARDS :-
 INSTRUCTIONS ;-
 Maximum of 3 members can participate in 1 KAIZEN depending upon size of KAIZEN
and role of each participant
 Approving superior has to confirm role and requirement of every participant in a
KAIZEN if participants are more than 1
 Approving superior has to confirm approval or rejection of KAIZEN within specified
time limit
 To empower and encourage employees It is recommended that an escalation matrix to
be made and followed if approver is not responding in specified time limit
 After implementation of KAIZEN successfully, administrator has to give 1 point to each
participating member.
 It is also recommended that administrator should visit monthly and check implemented
KAIZEN are being used and are well maintained in respective areas after
implementation.

KAIZEN
 PROCESS FLOW FOR ADMINISTRATION :-

KAIZEN
 KAIZEN PROCESS FLOW - M/S JABIL CIRCUIT INDIA PVT LTD :-

KAIZEN
 KAIZEN PROCESS FLOW - M/S JABIL CIRCUIT INDIA PVT LTD
 INSTRUCTIONS :-
 Every member of management staff has online account on KAIZEN portal, they can
check status of KAIZEN, reward points balance online by logging in to that account.
 Non management staff member, contract workers, production line workers report their
KAIZEN to their immediate supervisors for uploading it.
 Administrator used to keep record of such KAIZEN offline and review it quarterly.

KAIZEN
 KAIZEN TITLE : Div/Dept. :
Date Initiated : DD/MM/YYYY
Kaizen Leader :- Planned completion date : DD/MM/YYYY

Before Kaizen After Kaizen Support Team :-

1)

2)

<IMAGE> <IMAGE>

Waste Attacked

Transportation

Inventory

Movement
Problem/Opportunity Seen: Action/ solution Proposed:
Waiting

Overproduction

Over Processing

Defects

Results (Achieved/Expected) Additional comments :- (Savings, other Skills Unused

impacts, cost involved etc)
Metric Before After % Improve

Presented by in Arial 14 pt New Kaizen Replicate

Date and Place of Presentation in Arial Italic 11 pt

12
DIV/DEPT/FY15/K/XXX
 KAIZEN SUGGESTION FORMAT :-

Microsoft Office
Word Document

KAIZEN
 The PDCA Cycle for PRO+Active

●
Process Guardian ●
Process
●
Advisory
●
Custodian Developer
●
Continuous Improvement ●
Creator
●
Periodic Review ●
Documentation

Plan Do

Act Check
●
Process Owner ●
Process Auditor
●
Acceptance ●
Process Audit
●
Implement and Run the Process
●
Foresee and Seek Changes
●
Non Conformance
●
Preventive and Corrective Action ●
Escalate & Drive Preventive and
●
Training Business & operational end users Corrective Actions
Elevator Systems Organization Chart 2015-16
 Questions…???

KAIZEN
 THANK YOU

KAIZEN
 Generally following tools are used for generating KAIZEN.
 Knowledge of these tools would be an added advantage for developing KAIZEN CULTURE.
 Many ideas may emerge by knowing these tools.

KAIZEN
TOOLS

QC
5S
TOOLS
Pareto Method
80-20 rule study
Poka Brain-storming
Yoke
Value Stream Fishbone
Mapping Diagram
Gemba5Why
walkanalysis
KAIZEN
 KAIZEN PROCESS FLOW - M/S JABIL CIRCUIT INDIA PVT LTD
 INSTRUCTIONS :-
 Every member of management staff has online account on KAIZEN portal, they can
check status of KAIZEN, reward points balance online by logging in to that account.
 Non management staff member, contract workers, production line workers report their
KAIZEN to their immediate supervisors for uploading it.
 Administrator used to keep record of such KAIZEN offline and review it quarterly.

 Rewards given to employees were :-

No. of points Reward

5 Ball Point Pen - (JABIL Engraving on it)

10 Set of 2 Pens - JABIL Engraving on it)

15 Pen Drive/Memory card

20 Thermos bottle

30 Iron

50 Certification + BBL KAIZEN T Shirt/ BBL Bag etc

KAIZEN