kaizen technique

WELCOMEEngr. Abdun [email protected] ConsultantCentre for Management DevelopmentSEL Centre (6th Floor), 29-West Panthapath, Dhaka-1205, Bangladesh [email protected]

Engr. Abdun Noor, Centre for Management Development, [email protected]

TRAINING ON:TRAINING ON:


What is KAIZEN?


What is KAIZEN? SSmall andmall and un-dramatic improvement and its un-dramatic improvement and its

results are seldom immediately visibleresults are seldom immediately visible, but it is , but it is continuous thus brings good resultscontinuous thus brings good results

KAIZEN employs simple ideas and common senseKAIZEN employs simple ideas and common sense KAIZEN is based on the simple principle that we

need continuous improvement in order to progress and advance

The KAIZEN strategy is that ‘not a single day should go by without some kind of improvement’.


KAIZEN is: Making small improvements with little costMaking small improvements with little cost Making small improvements all the time - always Making small improvements all the time - always

thinking of doing something better today than thinking of doing something better today than yesterdayyesterday

Allowing everyone to make improvements


What is KAIZEN?KAIZEN inspire to KAIZEN inspire to Think outside the boxThink outside the box Think in a different wayThink in a different way Bring out CreativityBring out Creativity


How Improvement is Made?

Innovation/ ModernizationInnovation/ Modernization

& & KAIZENKAIZEN


KAIZEN and Innovation/ Modernization :

KAIZEN signifies small improvements made in KAIZEN signifies small improvements made in the status quo as a result of ongoing effortsthe status quo as a result of ongoing efforts

Innovation/Modernization involves a drastic improvement in the status quo as a result of a large investment in new technology, product and/or equipment

While KAIZEN is a continuous process, innovation is generally a one-shot phenomenon

KAIZEN does not necessarily require sophisticated technique or call for a large investment to implement it.


KAIZEN and Innovation/ Modernization :

TIMETIME

TIMETIME

KAIZENKAIZEN

Innovation/ Modernization Innovation/ Modernization


Why KAIZEN? One of the famous Parkinson’s Laws is that “An

organization, once it has built its edifice, begins its decline.”

Therefore, there must be a continuing effort for improvement to even maintain the status.

Even when modernization / innovation makes a radical improvement in standard of performance, the new performance level will decline unless the standards is constantly challenged and upgraded


Why KAIZEN?


Why KAIZEN?

What should be What should be (standard)(standard)

What actually What actually isis

Innovation/Innovation/Modernization Modernization

TimeTime


KAIZEN & Management Innovation/

Modernization

KAIZEN

Maintenance


Targets of KAIZEN KAIZEN targets for 3Ms for improvementKAIZEN targets for 3Ms for improvement

11stst M MMUDAMUDA

無駄無駄WastageWastage

(Avoid all (Avoid all wastage)wastage)

22ndnd M MMURIMURI

無理無理 StrainStrain

(Causing (Causing in-efficiency in-efficiency avoid strain, avoid strain,

work work smarter)smarter)

33rdrd M MMURAMURA

斑斑 ErrorError

(Avoid errors/ (Avoid errors/ Discrepancies, Discrepancies, Think Poka-Think Poka-

Yoke)Yoke)


KAIZEN KAIZEN employs simple ideas and common

sense KAIZEN is more a mind-set than a technique

(Positive mind set) A mind-set that “there is always a better way of

doing something.”


KAIZEN Checklist (Sample)


KAIZEN


KAIZEN Example:Productivity Improvement of Packaging Material in a Biscuit CompanyProductivity Improvement of Packaging Material in a Biscuit Company

Sl No

Name of materials and existing dimensions

Existing cost (Tk.)

Proposed Dimension

Savings (Tk.)

1. Grease Paper (24 no) 25.3 16.6 cm

1.52 25.3 15.24 cm. 0.17

2. Coloured Cellophane (24 no)19.3x16.5 cm

2.39 18.3 16.5 cm. 0.12

3. Polythene bag (1 no)4341cm

0.48 39.5 43 cm. 0.02

4. Batch coupon 1 no 0.01 Ok. - -

5. M.P.P. (Solid) Carton21.7 21.1 12 cm.

2.79 Ok. - -

6. Gum tape 1½ cm. 0.09 Ok. - -

7. Gm Tape 0.08 Ok. - -

Tk. 7.36 per Carton Tk. 0.31 Per cartonYearly production = Yearly production = 469885 Carton469885 CartonYearly Savings Yearly Savings = = Tk. 0.31 Tk. 0.31 46988 = 46988 = Tk. 1, Tk. 1, 45,664.3545,664.35


Before KAIZEN?A pool (Sheep dip) was used to remove insects from the sheep’s A pool (Sheep dip) was used to remove insects from the sheep’s bodies. We had to push the heads of the sheep down to submerge bodies. We had to push the heads of the sheep down to submerge them into the water mixed with insecticide. them into the water mixed with insecticide.


After KAIZEN?A pit was made at the bottom of the pool. This meant the sheep A pit was made at the bottom of the pool. This meant the sheep would submerge their heads by themselveswould submerge their heads by themselves


Before KAIZEN?


After KAIZEN?

AfterAfter


Before KAIZEN?


After KAIZEN?


Before KAIZEN?


After KAIZEN?


More KAIZEN examples?

Few examples from daily life?

Bus supervisor example CNG driver example Coconut leaf-fan example V-belt example


Examples of Poka-Yoke


Examples of Poka-Yoke: KAIZEN


Few examples of KAIZENBefore KAIZEN:

There was a strain in mounting the Bracket bellow support on to slim3 machine. 2 persons required to assemble the cover

After KAIZEN:Fixture made by using simple frame from in-house parts. Single person can assemble the cover. Easy handling of part since crane will be used



The storage of spindle shafts was being done with the help of a wooden V block fixture. This method was prone to damages

After KAIZEN:Special trolley introduced for storage of spindle shafts. Easy handling of spindle shafts. No damages will be caused during transport



CMM probe was kept on a surface table. Due to this being a regular working area there were chances of probe getting damaged . The probe is very expensive and costs

After KAIZEN:Probe damage avoided completely. House keeping also improved on CMM surface table



There was no fixture for proximity tightening

After KAIZEN:Two holes made on the table so that proximity can be fixed while tightening the connectors


Few examples of KAIZEN: Before


Few examples of KAIZEN: After


Lower the table

Raise the table

You can’t change the Table height

Few examples of KAIZEN

Footstool

Easy to work.


Few examples of KAIZEN

kaizen technique

Engineering