HO CHI MINH UNIVERSITY OF TECHNOLOGY FACULTY OF MACHINE INDUSTRIAL SYSTEM ENGINEERING

KAIZEN

MASTER GROUP
01/04/2012 nhm chuyn gia

NGUYEN NHU PHONG 13 LUU THANH DAT 20600456 DO MINH HOANG 20600778

What does Kaizen Mean?

Japanese term
Kai means Change
Zen means for the better

Kaizen: Continuous Improvement Concept

Small incremental improvements

Improvements add up over time

What is a Kaizen Event?

Continuous Improvement Event
Dedicated Resources Specific Goals

Short time frame

Also known as Kaizen Blitz

(lightning fast improvement )

Why Use Kaizen?

To solve problems To eliminate waste

Create ownership
Support lean thinking

Taiichi Ohnos 7 Wastes

Over - Production
TEN PLEASE!
CALL IT TWENTY? 22 TO BE ON THE SAFE SIDE!

Motion

Over -Processing
How do you spell that?

2
KO A O R T D K PE A ING SY E ST M

KO A O R T G S S E D K PE A IN Y T M

Defects / Rejects / Re-work

K D K O E A IN S S E O A P R T G YTM

KO A O E A IN S S E DK P R T G Y TM

4
Waiting

Transportation
$

Inventory
$

$ $ $ $
$

$
$

KO A O RA ING SY E D K PE T ST M

KO A O RA IN S S E D K PE T G Y T M

KO A O R T G SY E D K PE A IN ST M

What is a Kaizen Workshop?

A short burst of intense activity & effort (can range in hours to days)

Emphasis on action over analysis

Focused on improving the Value Stream and achieving flow Driven to resolving a specific problem or achieving a specific goal.

What is a Kaizen Workshop?

A Kaizen Workshop is Characterized by

A focus on an area or process to achieve a specific goal. Includes a team that is empowered to make changes. Team make-up should include: Operators, Maintenance, Outside Eyes, and a process owner.

Supported by management with Money, Time.

Kaizen Preparation
1. Define the opportunity
Cost, Quality, Waste

2. Form & train the team

They must be dedicated resources commitment They must be trained in specifics regarding the task at hand.

3. Set goals / collect baseline data

Is the problem well understood what does success look like? 4. Leader & team responsibilities

How Are Kaizen Teams Formed?

Team composition & training is critical to the success of the team Composition should reflect the diversity of the work center A team generally consists of 6-10 people Each member will be chosen to perform a specific role everybody works

Kaizen Cycle
Start Here
Do It Again

Document Reality

Celebrate

Identify Waste

Make this the Standard

Plan Countermeasures

Measure Results

Kaizen
Reality Check Make Changes Verify Change

Six Basic Rules of Kaizen

1. Respect others

2. Document reality
3. Do your share

4. Try something new

5. Ask why (the 5 whys)

6. Be safe / Think safe

Tools for Kaizen Blitz Projects

1. Benchmarking 2. Pareto Charts 3. Cause and Effect diagrams 4. Brainstorming 5. Process Mapping 6. Spaghetti Diagrams 7. Internal vs. External time/steps 8. Root Cause Analysis (5 Whys)
Chicago Manufacturing Center

16

What is the goal of an Event?

Improve an area of the business
Process Waste Reduction

Space Reduction
Labor Efficiency Quality or Mistake Proofing

Output Improvement

Manageable
Pick items that can be done right away

Employee Involvement
Culture change Trying out ideas

What happens during an event?

Planning
Week 1
Select project & team leader Communicate with target areas

Week 2
Select team members, define scope & goals Write work plan/charter

Week 3
Confirm commitments & gather some data Re-communicate with target areas

What happens during an event?

Week 4 Event Week
Day 1
Training for event Map & assess current state

Day 2
Determine improvements, implement

Day 3
Pilot changes

Day 4
Review project Present to management

What happens during an event?

Weeks 5, 6 & 7 Follow up
Prioritize open action items Report to management & core team
Open Items Achievement of goals

Additional event if necessary Close out project & document

Archive work plan Scan all data collected

Everyone and Everything Wins

Front line staff

Organisation

Customers

Better process Ideas for change Being listened to and allowed to shape the process I work in

Key indicators improved Quality Cost Delivery Safety Morale

Increased Satisfaction Better quality Better predictability Lower costs

Questions & Answers