KAIZEN SYED MOHAMMAD HASSAN

NOUKHAIZ ASLAM

AWAIS AHMED

ABUZAR KHAN

WHAT IS KAIZEN?

A Japanese term for improvement.

Derived from two terms KAI meaning Change ZEN meaning Continuous Improvement

Improvement in Manufacturing Engineering Business management

First implemented in Japan.

Involves all employees.

PDCA MODEL

System for executing Kaizen.

Four step management model.

The acronym stands for Plan Do Check Act

KAIZEN'S ADVANTAGES

Reduces waste

Improves employee utilization

Improves production

Reduces completion cycle time

Higher job satisfaction

PERSONS INVOLVED

Praise and encourage participation.

People at every level are involved.

The key people involved are;

The subject matter expert The process owner Front-line workers An outside novice

IMPLEMENTING KAIZEN

A critical business issue is identified.

A Project Leader is selected.

Project Leader selects a team

Train the event team

Gather data and facts

Report and implementation plan is created.

Implementation on small scale.

A Final Report is presented

TOYOTA PRODUCTION SYSTEM

Kaizen resulted from the competition between Nissan and Toyota.

Nissan won 'Deming' prize in 1961.

Toyota became more aggressive.

Developed the Toyota Quality Circles in 1962.

TECHNIQUES USED IN TPS

The Production Cell

Just in Time (JIT)

Total productive maintenance

5s

Single Piece Flow

Quality Control Circle

Waste

KAIZEN COSTING

Kaizen costing techniques are used in TPS.

Used to manage cost and standard time.

Director of the Production Division is responsible.

A Cost Council held every month.

KAIZEN PRODUCTION EFFICIENCY

MANAGEMENT

Toyota production line “Shôjinka”.

Group leaders are in charge of reducing the cycle time.

Increasing production efficiency.

Lowering production cost.

KAIZEN MIND

Workers are encouraged to suggest ideas.

Thinking about workplace is important.

Such voluntary activities increases efficiency.

Helps to obtain the abilities required for becoming supervisory.

KAIZEN FOR MAKING ASSEMBLY WORK

MORE ATTRACTIVE

A new concept of assembly line developed.

Assembly line was divided into about ten segments.

A buffer between two segments.

Group leader is allowed to stop the segment during the buffer.

A group can hold a meeting during buffer time.

Each segment also has a quality checking post.

PIT FALLS IN KAIZEN

Resistance to change.

Lack of proper procedure to implement.

Too much suggestion may lead to confusion and time wastage.

RECOMMENDATIONS

Employees consent and views must be taken into account.

Use of well defined procedures.

Well defined procedures must be observed.

THANK YOU