Professional Documents
Culture Documents
Kaizen
Kaizen
Kaizen
THE FIVE FOUNDATION ELEMENTS OF KAIZEN Teamwork. Personal discipline. Improved morale. Quality circles. Suggestions for improvement.
Storming Open & honest discussion, also brainstorming Norming Stage where the group agrees how to
operate as a team
Performing Agreement on solutions & taking action Adjourning Closing on the continuos improvement process
after 30 days
OUT OF THIS FOUNDATION, THREE KEY FACTORS IN KAIZEN ARISE Elimination of waste (muda) and muda) inefficiency. The Kaizen five-S framework for good fivehousekeeping. 1. Seiri - Sort 2. Seiton - Straighten 3. Seiso - Sweep 4. Seiketsu Sanitize (Safety) 5. Shitsuke - Sustain Standardization. Standardization.
Sort Straighten
Sweep
Organizing the way things are put away with efficiency, quality, and safety in mind. Need to decide where and how things should be put away and what rules should be obeyed to insure that it is maintained. Sweeping, scrubbing and cleaning of the building, machines, fixtures & tools so that all areas of the workplace are neat & tidy. This leads to early detection of mechanical problems before they become major breakdowns. Machines cry!
Sweep
(Scrubbing clean)
Insuring that each workplace is properly designed for safety. This is to protect every member from the dangers during the performance of their assigned tasks. Developing the practice necessary to continually participate in the 5S process. This requires that each of the Ss become a personal habit. This is the most difficult of the 5Ss, but it is the most important factor in achieving long term success. Establishing routines and procedures for maintaining and improving on the first four (Ss), incorporating visual management tools.
Sustain
(Standardize)
Reducing the overall time from receiving the order to delivering the product makes your company more responsive to the customer. This can become the deciding factor when the customer makes their selection. As can be seen, manufacturing is only one part of the entire process. Inputting, processing, and issuing orders is an area for improvement, as well as, assembly, loading and delivery to the customer`
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VA 1/2 %
Results of Common Improvement efforts, did not improve response time. VA time is reduced, but, the costs for those improvements in lead time was substantial.
Non-Value Added Time (NVA) 99% of Total Lead time NVA Time 95% of Total Lead time VA 5%
Great Job!!
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WASTE
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Staffing Waste
Productivity Productivity
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SHIFT MINDSET
CURRENT THINKING REQUIRED THINKING
Processing Transportation
Inventory
WASTE
Waiting
TYPES OF WASTE
Correction OverProduction
Motion
WASTE IS "TANGIBLE IDENTIFY MANY SMALL OPPORTUNITIES -LEADS TO LARGE OVERALL CHAGE CONTINUOUS IMPROVEMENT
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ELEMENTS OF WASTE
Definition
1. Transportation - Transporting farther than necessary or temporarily locating, filing, stacking and moving parts (people, paper, information) is waste. 2. Correction - Doing something over is waste. 3. Overproduction - Generating excess paper or information, or generating information or paper too soon in a process is waste.
Example
1. Transportation - Carrying Tools to Point of Use
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ELEMENTS OF WASTE
Definition
4. Motion - Unnecessary work movements are a form of waste.
Example
4. Motion - Tools in drawers
5. Waiting - Waiting for people, 5. Waiting - Meetings to start paper and information is waste it stops work. 6. Inventory - Too much of anything is waste. 7. Processing - this is waste in the process itself. Redundant activities 6. Inventory - Supplies
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