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GEMBA KAIZEN

By
Ismail Clement
http://gembakaizenemailconsulta
ncy.weebly.com/
1 Gemba Kaizen Email
Consultancy
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GEMBA KAIZEN
1. INTRODUCTION
2. GEMBA KAIZEN
3. HOW TO MANAGE
QCD IN GEMBA
4. STANDARDS
5. 5 S
6. MUDA
7. THE FOUNDATION OF
THE HOUSE OF
GEMBA
8. VISUAL
MANAGEMENT
9. SUPERVISORS ROLE
IN GEMBA
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CHAPTER ONE

INTRODUCTION
TO
GEMBA KAIZEN
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What is Kaizen?
Kaizen means change for the better in Japanese. The
best English equivalent is improvement'. Kaizen is
made up of two characters:

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Where did kaizen
originate?
Kaizen as we know it in Lean
Manufacturing originated at Toyota
Motor Company.
Many of the concepts and tools of
kaizen came from industrial
engineering and Dr. Edward
Deming's teachings. Masaaki Imai's
book 'Kaizen' made it a common
word outside Japan back in the
1980s.
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DEFINITION OF LEAN
Lean manufacturing is a strategy in
remaining competitive through the
endless pursuit of waste elimination.
1. Focus on the customer
Who are the external customer?
What is an internal customer?
What is the value to the customer?
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CONT
2. Eliminate the 7 waste of production.
What are the 7 waste?
What causes the waste?
How do we eliminate waste?
3. Do more with less
How can we increase value?
How to waste less resources?
How can we do both?
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Is Kaizen a shop floor
thing?
No. Kaizen is a way to improve any
process. Kaizen is about creating a
company culture that does not
tolerate waste. Kaizen efforts
typically start on the Gemba (in
production or where the value is
added) and extend across the entire
enterprise.
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Kaizen is a Japanese word. What
if I dont want to use that word?
What you call kaizen doesnt matter
so much as understanding what it is
and doing it right. Most people that
have a problem with the word kaizen
either haven't experienced what
kaizen really is or will never be
convinced anyway.
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Is Kaizen against
technology?
No. Technology and kaizen go hand
in hand. Kaizen encourages the
simple, low cost solution first, but
recognizes that technology may be
the better kaizen. Eliminating a
process will always have a greater
impact than just process
improvement.
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Is continuous improvement.
The KAIZEN philosophy - is our way of
life and should focus on constant
improvement efforts.
The improvements are small and
incremental.
KAIZEN process are based on common
sense and low cost approaches.
RUSSIAN
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MAJOR KAIZEN CONCEPTS
1. KAIZEN and management.
2. Process versus result.
3. Following the PDCA/SDCA.
4. Putting quality first.
5. Speak with data.
6. The next process is the customer.
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KAIZEN AND MANAGEMENT
Has two major functions: Maintenance
and Improvement.
Maintenance: current technological,
managerial and operating standards.
Improvements: activities directed
toward elevating current standards.

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Japanese Perceptions Of Job
Functions
Top management


Middle management Improvement



Supervisors Maintenance



Workers
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KAIZEN n TECHNOLOGY
Whenever money is a key factor,
innovation is expensive.

Kaizen emphasizes human efforts,
morale, communication, training,
teamwork, involvement and self discipline
a commonsense low cost approach to
improvement.
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Improvement Broken Down Into
Innovation
Top management Innovation


Middle management Kaizen



Supervisors Maintenance



Workers
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PROCESS VERSUS RESULT
Kaizen fosters process-oriented thinking.
Kaizen focuses on human efforts
A process-oriented approach should also be:-
PDCA
SDCA
QCD
TQM
TPM

Kaizen strategies have failed many companies
simply because they ignored process.
The most crucial element in the kaizen process is the
commitment and involvement of top management.






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Following the PDCA/SDCA Cycles
The first step in the kaizen process
establishes the PDCA cycle.
Plan refers to establishing a target for
improvement.
Do refers to implementing the plan.
Check refers to determining whether the
implementation remains on track.
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Cont.
Act refers to performing and
standardizing prevent recurrence of the
original problem or to set goals for the
new improvement.
The PDCA cycle revolves continuously.
Management must initiate PDCA by
establishing continuously challenging
goals.
Before working on PDCA, any current
process must be stabilized.

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Cont.
Every time an abnormality occurs in the
current process, the following questions
must be asked:
Did it happen because we did not have a
standard?
Did it happen because the standard was
not followed?
Did it happen because the standard was
not adequate?
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Cont.
SDCA standardizes and stabilizes the
current process.
PDCA improves the current process.
SDCA refers to maintenance and PDCA
refers to improvement, these become the
two major responsibilities of
management.
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IMPROVEMENT - PDCA
P

D
A
C
PLAN
ACT
DO
CHECK
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MAINTENANCE - SDCA
s A
D
C
STANDARDIZE
ACT
DO
CHECK
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PUTTING QUALITY FIRST
Of quality, cost and delivery, which
should always have the highest priority?
? concept requires management
commitment.
Managers often face the temptation to
make compromises in meeting delivery
requirements or cutting cost.
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SPEAK WITH DATA
KAIZEN is a problem solving process.
The problem must be understood and
recognized.
Solving a problem without data is not a
very scientific or objective approach.
Collecting, verifying and analyzing data
for improvement is vital.
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THE NEXT PROCESS IS THE
CUSTOMER
The next process should always be
regarded as the customer.
Refers to two types of customers: internal
and external.
When everyone in the organization
practices this the external customer will
receive a high quality product or service
as a result.
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MAJOR KAIZEN SYSTEM
The following major systems should be in place
in order to successfully achieve a Kaizen
strategy.
Total quality control / total quality management.
A just in time production system.
Total productive maintenance.
Policy deployment.
A suggestion system.
Small group activities.
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TQC / TQM
One of the principles of Japanese management
has been TQC in its early development.
This has evolved into a system encompassing
all aspects of management and is now referred
to as TQM a term used internationally.
TQC / TQM should not be regarded as strictly
as a quality control activity: It has developed as
a strategy to aid management to be more
competitive and profitable by helping it to
improve in all aspect of business.

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Cont.
Q meaning quality, has priority but there
other goals too namely cost and
delivery.
T signifies total, meaning that it
involves everybody in the organization.
C refers to control or process control.
In TQC/TQM key process must be
identified, controlled and improved on
continuously in order to improve results.
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TQM



Quality assurance




Quality control




inspection

Aim for continuous improvement / Involve suppliers &
customers / Involve all operations / Performance
measurement / Team work / Employee involvement

Third party approval, systems audits, advanced
quality planning, involvement of non production
operations, failure mode and effect analysis,
statistical process control
Develop quality manual, process performance
data, self inspection, product testing, basic quality
planning, use of basic statistics, paper work
control
Salvage, sorting, grading, corrective actions,
identify sources of non conformance
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