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Be it our working life, our sociallife, or our home life, deserves to

be constantly improved

K IZEN PHILOSOPHY

Kai-Zen Continual Improvement


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Kaizen-make it a little better

Its an incremental Improvement

Kaizen
http://images.google.com/imgres?imgurl=http://smartmortgageadvice.files.wordpress.com/2007/05/pennies-01_www.jpg&imgrefurl=http://brightest-kidz.squarespace.com/journal/2008/1/17/coin-powered-battery-project.html&usg=__L1718AcvKGzwIYwwSlnRrNlwwog=&h=900&w=900&sz=100&hl=en&start=18&tbnid=twyAdDT09Wr35M:&tbnh=146&tbnw=146&prev=/images%3Fq%3Dpile%2Bof%2Bpennies%26gbv%3D2%26hl%3Den


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KAIZEN INNOVATION

Long termUn-dramatic

Effect Short termDramatic

Small steps Pace Big steps

Continuous & incremental

Time

frame

Intermittent &

non incremental

Gradual & consistent Change Abrupt & volatile

Everybody Involvement Champion

Collectivism,

group efforts, systemsapproach

ApproachRugged individualism,

individual ideas & efforts

Kaizen Vs Innovation


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Innovation

Maintenance

Maintenance

Standard

Standard

Actual

Actual

Time

Innovation Standard

Standard

KAIZENActual

Actual

KAIZEN

Time

Innovation

Innovation + Kaizen

Kaizen +Innovation

// YIS//062709//


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-An outstanding performance award-A skill award

-A fighting spirit award

Focus more on process

Rather than result !!!

Kaizen Steps


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Internal | NaP/BPS-CIP | 16/01/2013 | Bosch Limited 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,

distribution, as well as in the event of applications for industrial property rights.

SFC Board Layout Tool for potential analysis

TeamDetails1 2 3

4 5

7

Caretaker Name & Tel

Problem Bank Selection Criteria

12 Steps & Road Map Problem solving sheet

Savings

6 Working sheet

9 Summery Sheet

10

8 KPI Tree sheet


11/2211Internal | NaP/BPS-CIP | 16/01/2013 | Bosch Limited 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,


SFC Team & Meeting / Attendance

SFC Meeting

Every _____ at _____

Time : ____ to ____

Team Name: -

Team Photo Name E no.

Attendance:

Agenda:

11




Problem Bank

Sr.

No.Date Problem Name Sign.

Type

(A,B,C)

12




Problem Selection criteria

Problem Selection criteriaSr. No Problem Quality

10

Cost

10

Delivery

10

Safety

10

Business

Case

10

Total

1. 10 5 5 0 0 20/50

2. 4 0 2 0 0 6/50

3. 0 5 0 10 0 15/50

Inscription Rolling not

done.

Filter pin pressing

Coolant overflow at filter.

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Rating:

Maximum points can be given - 10Minimum points can be given - 0


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Problem solving sheet

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Problem solving sheet / samasyaa inavaarNa t@ta

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Working sheet

Data collection & Analysis sheet

How data is collected

Which tool is used for data collection

How collected data is analyzed

How collected data is Validated

Instructions regarding who will do what before next meeting

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SFC Results

Savings:

1.Tangible.

2. Intangible.

3.Before / After Graphical Tracking orPictures

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NaP/BPS-CIP |16/01/2013| Bosch Limited 2013 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,

as well as in the event of applications for industrial property rights.

Before / After Pictures

DD.MM .YY

Machine /area name

1. Describe here what is tochanged & why

1. Describe changed what , andwhat is achieved after change

Product-

Photo Before change, mark

to be changed in Red

circle- see examples on

best practices, dotted bold

line

Photo after change-

Mark change in green

circledotted bold line

Mark below P- productivity- Q-Quality,

C- Cost , D delivery to next & external

customer& SHE- Safety , Health ,Environment- improved Morale- effect

of action

Name who did it !

Date: Range & Work shop : W

Place Description

:

AFTER

Impact on :

BEFORE

SHEDCQ

Responsible :

Range :

P

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KPI Tree

Product Cost

(PHEK)

COST DELIEVERY

Productivity Tool Cost Maint. Cost

OEE

VaO/WH

Tool cost

Monitoring

GEZ WIP

MTTR

MTBFWheel life

Improvement

QUALITY

Defect cost

Scrap

improvemnt

N 903

from 1459

to 572

N 904

DELIVERY

FUFILMENT

Typewise


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Best process/best result from NaP Summery sheet

Description of the idea/ solution

Major actions are:Result :

16/01/2013 | This is an exclusive property of Bosch Limited, India.

Without their consent, it may not be reproduced or given to third parties.

Product: Area :

Department: Line:

Contact :

Description of the problem

Transferability :

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