TRAINING ON

KAIZEN
SUKIN.S.SHETTY
KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

TOPICS TO BE DISCUSSED

INTRODUCTION OF KAIZEN
7 TYPES OF WASTES
WHY KAIZEN
8 KEY ELEMENTS OF KAIZEN CULTURE
KAIZEN MINDSET
TOYOTA PRODUCTION SYSTEM
BENEFITS OF KAIZEN
HOW TO IMPLEMENT KAIZEN

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

INTRODUCTION
KAIZEN MEANS CONTINUOUS IMPROVEMENT
IN JAPAN :

KAIZEN
KAIZEN TRAINING

CHANGE FOR BETTER

TOKAI RIKA MINDA INDIA PVT LTD

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

TPS created KAIZEN based on DEMINGS cycle or PDSA cycle

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

MAKE EVRYTHING AS SIMPLE AS

POSSIBLE BUT NOT SIMPLER

-- ALBERT EINSTIEN

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

KAIZEN is a system of continuous improvement in

quality, technology, process, company culture,
productivity, safety and leadership.
KAIZEN was developed in 1950 after the world war-II
by TAIICHI OHNO and SHIGEO SHINGO based on
DEMINGS CYCLE or SHEWART CYCLE or PSDA
CYCLE.
KAIZEN involves setting standards and then
continuously improving those standards

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

DEMINGS CYCLE

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

KAIZEN TRAINING

TOKAI RIKA MINDA INDIA PVT LTD

DEMINGS CYCLE
DEMINGS CYCLE or SHEWART CYCLE or PSDA
CYCLE found by EDWARDS DEMINGS AND WALTER
SHEWART
It is a continuous quantity improvement model
consisting of a logical sequence of four repetition
steps for continuous improvement and learning
PLAN

PLAN AHEAD FOR CHANGE. ANALYSE & PREDICT

RESULTS

DO

EXCUTE THE PLAN TAKING SMALL STEPS.

STUDY

CHECK AND STUDY THE RESULTS

ACT

TAKE ACTION TO STANDARDIZE

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KAIZEN CYCLE
START
HERE

IDENTIFY WASTE

PLAN COUNTER
MEASURES

CELEBRATE

MAKE
STANDARD

REALITY CHECK

VERIFY
MAKE CHANGES

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7 types of wastes

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7 types of wastes

waste

MUDA

1. Over production -- Production more than required.

2. WAITING Process delays idle time.
3. TRANSPORTATION Delay in material handling.
4. EXCESS INVENTORY Excess of raw material & tools for
production.
5. Motion Actions of people or equipment that do not add value.
6. OVER PROCESSING Unnecessary stops or work elements or
procedures.
7. DEFECTIVE UNITS Production of a part that is scrapped or
require work.

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The foundation of Kaizen method consists of 5

founding methods :
1. Team work
2. Personal discipline
3. Improved Morale
4. Quality circles
5. Suggestions for improvement.

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Improved Morale :

Quality circles : Employee participation program.

It consists of employees who meet
periodically to identify strength and weakness in
production

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WHY KAIZEN
1. To eliminate waste in organization.
2. To increase productivity.
3. To improve quality
4. Customer satisfaction.
5. Growth of the organization.
6. To eliminate any abnormalities & stopping of limits
7. Developing self personality.

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8 KEY ELEMENTS OF KAIZEN CULTURE

1. KAIZEN MINDSET
2. CUSTOMER ORIENTATION
3. QUALITY CONTROL CIRCLES
4. SUGGESTION SYSTEM
5. DISCIPLINE IN WORKPLACE
6. SMALL GROUP ACTIVITIES
7. CO-OPERATIVE RELATIONS
8. TOTAL QUALITY MANGEMENT.

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KAIZENMINDSET
1. EVERYTHING CAN & SHOULD BE IMPROVED
2. NOT A SINGLE DAY SHOULD GO WITHOUT SOME KIND OF
IMPROVEMENT.
3. IMAGINE THE IDEAL CUSTOMER EXPERIENCE AND STRIVE TO
PROVIDE IT.
4. DONT JUST CRITICIZE,SUGGEST AN IMPROVEMENT.
5. THINK OF HOW TO IMPROVE IT INSTEAD OF WHY IT CANT.
6. SET TARGET AND MOTIVATE YOURSELF TO ACHIVE IT.
7. USE COMPTETION TO AROUSE INTEREST.
8. DONT LOOK FOR REWARDS.
9. GENERATE MORE QUESTIONS.
10. SAY YOURSELF I

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CAN DO IT
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TOYOTA PRODUCTION SYSTEM- TPS

TAIICHI OHNO and SHIGEO SHINGO developed TPS between 1948 and 1975.

They visited several FORD motor company automotive plants in Michigan.

But observed some methods not very effective . Then by chance they
visited supermarket Piggly Wiggly. They were inspired how the products
were re ordered and restocked goods. Reducing inventory by using just in
time ( JIT) inventory system. Using easy methods to display their goods
and arranging manpower only wherever required. They were doing good
business with less investment.
Main objective of TPS was :
1. Reduce inventory by following JIT.
2. Standardised work management.
3. Continuous improvement.
4. Lean manufacturing
5. Customer satisfaction
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KAIZEN ACIVITIES DIFFERENCES BETWEEN JAPAN AND

WEST

JAPAN

WEST
1. Deals with quality of
products.

1. Deals with quality of

products

2. Manufacturer oriented

2. Customer oriented.

3. Product oriented aimed at

detecting and eliminating
defected parts.

3. Process oriented aimed at

improving the total
performance.

4. Responsibility of quality
control managers.

4. Company wide, everybody

is responsible.

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BENEFITS OF KAIZEN
1. Savings in energy, material & others resources.
2. Improvements in working environment.
3. Improvements in machines & process.
4. Improvements in jigs & tools.
5. Capable of generating new ideas.
6. Customer satisfaction.
7. Elimination of wastes.
8. Improvement in product quality.
9. Improvement in 5S.
10.Improvement in self personality.
11.Improvements in own work..
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HOW TO IMPLEMENT KAIZEN

Employee identifies problem, waste or
an opportunity for improvement and
write it down

The employee develops an improvement

idea & discuss with his or her
supervisor

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The supervisor reviews the idea within

24hrs & encourages immediate action.

The employee implements the idea

The idea is written upon a simple Kaizen

sheet

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Supervisor publishes the Kaizen and rewards

will be given
CELEBRATE THE SUCCESS OF YOUR KAIZEN

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