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Created on February 2011

Kaizen for Lean manufacturing Chap2 : Kaizen Collection of Cases

Created by Japanese Gemba Kaizen Web

http://takuminotie.com/english/

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Table of Content

1. Kaizen example: Boxing

2. Kaizen example: Airborne Dust

3. Kaizen example: Cup Noodles

4. Kaizen Example of Visualization ①5. Kaizen Example of Visualization ②6. Kaizen Example of Visualization ③7. Kaizen Example of Visualization ④8. Kaizen Example of Visualization ⑤9. Kaizen Example of Visualization ⑥10. Kaizen Example of Visualization ⑦

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1. Kaizen example: Boxing

Present condition

Boxing heavy products.

Issue: Arms are tired.

Traditional thinking:

1. Get used to it very soon at first.

2. Try your best spirit!

3. There is no enjoyable job!

Nothing perfects come into existence from the maintenance of the status quo.

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Issue: The arms are in pain.

Arms are in in pain? Why?

1. No strength. - Suggestion: Muscle-building

2. Heavy products. - Suggestion: Make them light.

3. Lifting - Suggestion: Make them do not need to be lifted.

Make them do not need to be lifted.

1. Aiming of entering it on the top of the box.

2. Aiming of exceeding the height of the box.

Why?

Why?

Why?

1. Kaizen example: Boxing

Of not in pain.

Load

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1. Slide into the box horizontally. 2. Drop from the top.

Topic: Hard to do.

Topic: Worry for the impact of falling.

The approach of Kaizen is to find the optimal way in the innumerable constraints.

1. Kaizen example: BoxingKaizen approach 1

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1. Side slope into the box. 2. Lay a cushion on the bottom of the box.

Topic: The cushions

cost.

It does not cost if it can be

responded immediately.Cushion

Find the most suitable one out of the constraints!

1. Kaizen example: BoxingKaizen approach 2

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Change the work order.

Assemble the boxes, after that do not place the goods

into the box but assembles the products when the box is

plane.

1. Kaizen example: Boxing

Kaizen approach 3

It is better to assemble the products than not taken the empty space

reasonably before keeping the boxes planed as it is.

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2. Kaizen example: Airborne Dust

Rationalize the work and settlement to avoid airborne

dust caused by machining work.

Consider the steps of operating before implementing the operation.

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Damaged

noodles

3. Kaizen example: Cup NoodlesIssue: Frequent damage of the noodles in the process of inserting

noodles into the cups.

Remove the broken pieces of the noodles during the process of putting the noodles into the cup.

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4. Kaizen Example of Visualization ①

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Forget to turn the air-conditioner off. Attach the ribbon to the air outlet.

Cannot confirm with the eyes. Can confirm with the eyes.

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5. Kaizen Example of Visualization ②

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Forget to close the tap occurs. Change it to lever.

CloseOpenClose

Open

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6. Kaizen Example of Visualization ③

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Forget ordering occurs. Turn the order form over once

an order has made.

Order form Order

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7. Kaizen Example of Visualization ④

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After KaizenThe coffee has not served yet in an

order of a set of lunch and a cup of

coffee.

Prepare the spoon and plate

beforehand for the set served with

the coffee.

Order form 注文票

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8. Kaizen Example of Visualization ⑤

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Cannot manage the stationary of the

tools.

Implementation of the management

board.

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9. Kaizen Example of Visualization ⑥

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Does not know the screw is

loose.

Tightening of the loose screw

can be seen by eyes.

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10. Kaizen Example of Visualization ⑦

Human’s vision is the most developed among the five senses,

most of the information is getting through the eyes.

Before Kaizen After Kaizen

Does not know where had one

return the book.

Immediately return to the book’s

original position because there is a

mark on it.

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