Sop: Kaizen Implementation& Evaluation

Definition:
Any change in method, machine, man and material
which leads to improvement in a respective area
should be treated as “Kaizen”. Kaizen not only
ensures that manufacturing processes become
leaner and fitter but also eliminates waste where
value is added. In short change for betterment is
kaizen.
Objective
The objective of this SOP is to improve and
increase efficiency and productivity
continuously through system simplification,
process standardization, reducing waste and
incremental improvements by using techniques
like Kaizen.
Purpose
Kaizen shall ensure strong small, incremental
changes that shall be routinely applied and
sustained over a long period which shall result in
significant improvement.
Kaizen shall be applied to empower the workers,
increase worker satisfaction, facilitates a sense of
accomplishment and increase productivity.
 The Function of
KAIZEN
Planning the
remedial center
Generating Ideas to measures
Implementation of
solve problems
04 the improving project
03 05
Analysis and Measuring, analyzing
selection of the key and comparison of
problem 02 06 the results

Identify the Standardization

01 07
improvement area
 Techniques

01 TPM (Total Productive

Maintenance)

PDCA
02
 Techniques

TPM (Total Productive Maintenance)

approach shall ensure machineries
maintenance in three levels that strives to
achieve perfect production without:
Breakdowns
Small Stops or Slow Running
Defects
 Techniques
All levels of this TPM program are worth the
investment in time and money to ensure that
equipment can operate at optimum productive
levels and last the length of its life cycle.
TPM shall be applied at maximization of machine
utilization, operator, material, energy utilization,
reducing losses that affect work efficiencies.
 Responsible Person: Machine
operator
 Tasks include: Cleanup and
checking operating conditions
 Frequency of Performance: Daily
 Responsible
Department :Maintenance
 Tasks include: Total or partial
teardown of the machine for
repairs or replacing part
 Frequency of Performance: Once a
month

 Responsibility: Manufacturer of the

machine or third Party
 Tasks include:
 Frequency of Performance: Once a
year
 Techniques
 PDCA
Process of kaizen idea application shall be closed in
PDCA cycle, where:
1) P=Plan refers to establishing the aim for
improvement
2) D=Do is connected with implementing the plan
3) C=Check defines determining whether the
implementation has brought the planned
improvement
4) A=Act characterizes standardizing as the preventing
recurrence of the original problem or setting goals
for new improvement.
 5’s Concept

Kaizen shall maintain 5S concept

5S shall follow the below steps:
1) Seiri (Sort)
2) Seiton ( Set in order)
3) Seiso (Shine)
4) Seiketsu (Standardize)
5) Shitsuke (Sustain)
 5’s Concept
By applying 5s we shall remove items
that are:
Clean the area in order to
more easily identify
problems (shine)
03
Organize the items to Implement color coding and
optimize efficiency and 02 04
d labels to stay consistent with
flow (set in order) other areas (standardize)

Develop behaviors that

No longer needed 01 05
d keep the workplace
(sort) organized over the long
term (sustain)
 Kaizen Idea Generation

01 02 03

Cost- Manpower Energy

effectiveness Optimization Saving
Housekeeping Productivity “3Rs”
Safety & Increase (reduce, reuse
security Cycle time & recycle)
Space reduction
utilization Process
development