kaizen _short presentation
TRANSCRIPT
“The best solutions are the simple ones”
Masaaki Imai
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Kaizen
Short introduction by: Claudia (not Cloud-ia)
“The best solutions are the simple ones”
Masaaki Imai
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“For want of a nail the shoe was lost
For want of a shoe the horse was lost
For want of a horse the rider was lost
For want of a rider the battle was lost
For want of a battle the kingdom was lost
And all for want of horse-shoe-nail.”
“For Want of a Nail”
“The best solutions are the simple ones”
Masaaki Imai
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The micro processes determine the macro and mega results.
“For Want of a Nail”
“The best solutions are the simple ones”
Masaaki Imai
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Introduction to Kaizen, GEMBA Kaizen and Lean Manufacturing
1986 “Kaizen, the Key to Japan's Competitive Success”
1997 “Gemba Kaizen, A Commonsense, Low-cost Approach to Management”
2003 A new book to be published
Kaizen = continuing improvement in personal life, home life, social and working life.
Kaizen involves everybody.
Kaizen is achieved without spending much money.
Gemba = "real place", where the real action takes place.
“The best solutions are the simple ones”
Masaaki Imai
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Introduction to Kaizen, GEMBA Kaizen and Lean Manufacturing
Kaizen vs. InnovationKaizen INNOVATION
Small steps Conventional Know-How Efforts Process-oriented Slow-growth economy
Big steps Technological Breakthrough Investment Result-oriented Fast-growth economy
Innovation
Kaizen
“The best solutions are the simple ones”
Masaaki Imai
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The House of Gemba
The two major activities in Gemba:
maintenance of current technological, managerial and operating standards through training and discipline
improvement of the standards
Top Management Innovation
Middle Management KaizenSupervisors Maintenance
Workers
“The best solutions are the simple ones”
Masaaki Imai
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The House of Gemba
Standardization
5 S (Good Housekeeping)
Muda Elimination
Teamwork
Visual Management
Morale enhancement
QC circles
Self-discipline
Suggestions
Workers’ operations Information Equipment
Products & materials
Quality & Safety mgmt
Cost management
Logisticmgmt
Profit management
“The best solutions are the simple ones”
Masaaki Imai
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The House of Gemba. First Level: Muda Elimination
The 7 Muda Definition Examples
1. OverproductionProducing more than the customer needs right now
Producing product to stock based on sales forecasts Producing more to avoid set-ups
2. TransportationMovement of product that does not add value
Moving parts in and out of storage Moving material from one workstation to another
3. MotionMovement of people that does not add value
Searching for parts, tools, prints, etc. Sorting through materials Lifting boxes of parts
4. WaitingIdle time created when material, information, people, or equipment is not ready
Waiting for parts, prints, machines, information
5. ProcessingEffort that adds no value from the customer’s viewpoint
Multiple cleaning of parts Paperwork
6. InventoryMore materials, parts, or products on hand than the customer needs right now
Raw materials, Work in process, Finished goods
7. DefectsWork that contains errors, rework, mistakes or lacks something necessary
Rework, defects, missing parts
“The best solutions are the simple ones”
Masaaki Imai
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The House of Gemba. Second Level: 5 S – Good Housekeeping
Seiri Seiton Seiso Seiketsu Shitsuke
SortSort out what is
needed andwhat is not needed.
When in doubt throw it out!
StraightenKeep everything that is
neededin an orderly fashion so that
things can be accessed easily.
SweepClean the machines floors and
walls, looking for sources of filth.
Eliminate the sources.
StandardizeMake standards so that any
abnormality becomes obvious.
Self-DisciplineSustain the
improvementsto prevent
backsliding.
“The best solutions are the simple ones”
Masaaki Imai
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The House of Gemba. Third Level: Standardization
A
Act
C
P
D
Plan
DoCheck
IMPROVEMENT
A
Act
C
S
D
Standardize
DoCheck
MAINTENANCE
STANDARDS:
1. Represent the best, easiest, and safest way to do a job.
2. Offer the best way to preserve know-how and expertise.
3. Provide a way to measure performance.
4. Show the relationship between cause and effect.
5. Provide a basis for both maintenance and improvement.
6. Provide objectives and indicate training goals.
7. Provide a basis for training.
8. Create a basis for audit or diagnosis.
9. Provide a means for preventing recurrence of errors and minimizing variability.
“The best solutions are the simple ones”
Masaaki Imai
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“The Carrot Story”
The Carrot Diet: Eat one pound of raw carrots a half hour before every snack or meal.
Not one person in 100 is successful with the Carrot Diet, even for a day or two.
Why great initiatives often fail in organizations?
In the today competitive market, organizations encounter challenges that require Carrot Diet discipline.
Everyone realizes the importance of the carrot initiative and pledged their support.
“The best solutions are the simple ones”
Masaaki Imai
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“The Carrot Story”
The engineers decide they can take a beta-carotene pill each day.
Human Resources are concerned that meat lovers in the work force might be offended by the focus on a vegetable.
Computer Services recommend delaying carrot consumption until a tracking program is installed.
“The best solutions are the simple ones”
Masaaki Imai
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“The Carrot Story”
Accounting also suggests a delay in eating carrots. The Accounting Department discovered carrots were not in the budget and the accounting system did not have a line item to track carrot expenditures.
The president, who fully endorses the initiative, spends countless hours in support of the Total Company Carrot Plan (TCCP).
Everyone supports the concept, but few carrots are eaten.
“The best solutions are the simple ones”
Masaaki Imai
K
A
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Z
E
N
“The Carrot Story”
KAIZEN Success Factors:
COMMON SENSE, DISCIPLINE & LEADERSHIP
The secret of the Carrot Diet:
THERE IS NO ALTERNATIVE TO EATING THE CARROTS.