V.B.Shah Institute of Management: Fybba Sem-2 1 DIV

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V.B.

SHAH INSTITUTE OF MANAGEMENT

FYBBA SEM-2
1ST DIV

KAIZEN

改善 TO
SWATI MAM
'.
t'.

改 善
KAI ZEN
'change'
Or 'good'
'the action to correct'
Masaaki lmai is known as the developer of Kaizen.

Masaaki lmai born in tokyo 1930

In 1986 he founded the Kaizen Institute Consulting Group


(KICG) to help western companies to introduce the
concepts, systems and tools of Kaizen

Wrote best seller: “KAIZEN : KEY TO JAPAN’S COMPETITIVE SUCCESS”


Was traslated in 14 languages
 Kaizen means ” continue improvement“
So basically
kaizen is continue changes made for improving productivity
and
minimizing waste.

 it is guru mantra from Japanese industries and gift to world.

 'it means continuous improvement in


Quality, human resources ,production methods and
processes and management
Kaizen has three main principles
Human resources are the valuable
assets which requires continuous
improvement
There should be slow but continuous
improvement
There should be quantitative
evaluation of improvement
 We can see the reflection of Kaizen in Japanese cars,
music system, radio , TV , toys etc. The kaizen programme
can be divided into 2 parts :

 Part 1 :Management oriented Kaizen :managers are


are expected to improve their managerial efficiency in
decision making.

 Part : 2 : group oriented kaizen: it tries to improve


collective decision making and group activities.
Features of kaizen
1. Widely applicable:- Can be used in both manufacturing and
non-manufacturing environments

2. Highly effective& results oriented:- Kaizen events Will generate


quick results, Measurable results, Establish the baseline, and
measure the change!!!
3 A Learning Experience:- Every member of a Kaizen Team will
walk away from the event learning something new

4. Team based & cross functional:- Team members can be from


various functions of the business. Top management participation is
also encouraged.
Benefits of kaizen
1. Kaizen Reduces Waste like inventory waste,
time waste, workers motion

2. Kaizen Improves space utilization, product quality


3. Results in higher employee moral and job satisfaction,
and lower turn over

4. Toyota is well-known as one of the leaders in using Kaizen. In 1999


at one u.s plant, 7,000 Toyota employees submitted over 75,000
suggestions, of which 99%were implemented.
Kaizen elements
 PHASES IN KAIZEN
What is 5S and why do we want to do it?

Sorting Sweeping Sustaining

Simplifying Standardizing
 5 ’S’ in KAIZEN

1 Sorting:- keeping only essential items.

2 Simplifying:- eliminates extra motion.


5S Examples - Sort, Set in Order

See the difference?


1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
3 Sweeping:- keep the workplace clean

4 Standardizing:- standardized work practices

5 Sustaining:- maintaining and reviewing standards


5S Examples - Shine

3. Shine - The area is cleaned as the work is performed (best)


and\or there is a routine to keep the work area clean.
 Some 5S Examples

After 5S - Cleaned,
organized and drawers
labeled (less time and
Before 5S frustration hunting)
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S
 The Good

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