KAIZEN & LEAN MANAGEMENT

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 INTRODUCTION

KAIZEN is a Japanese word Meaning

KAI=CHANGE ZEN=GOOD

(CHANGE FOR THE BETTER)

KAIZEN = CONTINUAL IMPROVEMENT

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 The Toyota Production System

The Toyota Production System, and later on the concept

of Lean, was developed around eliminating the three
types of deviations that shows inefficient allocation of
resources. The three types are

 Muda means wastefulness

 Mura means unevenness,
 Muri means overburden

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 INTRODUCTION

THREE PILLARS OF PRODUCTION MANAGEMENT

 Total Quality Management (TQM)

 Total Productive Maintenance (TPM)

 Just-In-Time (Lean)

Kaizen is used in the implementation of all the above

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 KAIZEN

What is Kaizen
Kaizen Philosophy implies that
Whatever we do can be continuously improved, be it our working
life or personal life
Kaizen is some thing that anybody can do, everybody must devote
time for making improvements
Kaizen means looking at everyday work in a new way,seeking out
areas,aspects of work to improve upon.It represents the struggle
on the job and the means adopted to overcome these struggles –
with intuition, creativity, resourcefulness, common sense and
determination – to break the status quo

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 KAIZEN

Two Level of Kaizen

Senior System or Flow Kaizen

Manager /
Engineer
Supervisors

Workers
Process Kaizen

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 10 Principle of Kaizen
 Eliminate old practices
Improve everything continuously
Don`t accept excuses and make things happen
Don`t assume the new method will not work
Make corrections when you find any mistake
Empower employees to speak
Get information and opinions from multiple people
Use Why-Why analysis
Be lean & Economic
Never Stop improving

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 KAIZEN

Seven Wastes in a Factory

Wastes From :
Over Production
Waiting Time
Transportation
Processing
Inventory
Wasteful Motions
Product Defects
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 KAIZEN

Seven QC Tools
7QC Tools are :
Brainstorming and Cause & Effect Diagram
Check Sheet
Pareto Analysis
Graphs/ Stratification
Scatter Diagram
Histogram
Control Chart
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 KAIZEN

Sixteen Manufacturing Losses:

• These 16 manufacturing Losses are grouped into…

• Eight Major Equipment Losses

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• Five Manpower Losses

• Three Material Losses

LOSSES
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 KAIZEN

Sixteen Manufacturing Losses - Contd.

• Eight Major Equipment Losses:

1. Equipment or tooling downtime

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LOSSES
2. Set up loss
3. Start up & shut down loss
4. Other downtime loss
5. Slow cycle time loss
6. Minor stoppages
7. Rejects & rework
8. Scheduled downtime 11
 KAIZEN

Sixteen Manufacturing Losses:

• Five Manpower Losses:
1.
2.
Management loss
Line balance loss 16
LOSSES
3. Operator skill loss
4. Logistics loss
5. Inspection & adjustment loss

• Three Material Losses:

1. Material yield
2. Energy loss
3. Consumable material loss 12
 KAIZEN

Conclusion
Kaizen is a philosophy of Continuous Improvement. It is a never
ending process of creating Continuous Improvement culture in
Japanese companies. Toyota Japan developed this approach in
1940’s.
Gemba Kaizen : Gemba Means workplace where the real action
takes place. Gemba Kaizen means continuous improvement done at
work place in real time.
Kaizen Philosophy warrants one to go to Gemba in real
time.Whenever there is a problem, Make On the Spot improvements
rather than sitting in the ivory towers make a plan for
improvements. Normally plan remains without any action on it.
Gemba Kaizen stresses action with plan
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THANK YOU

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