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TOPIC :- KIAZENSUBMITTED BY:AMARJEET SINGHROLL NO:-RE47B1A03REG NO:- 7480070020
PRESENTATION OF TERM PAPER
Kaizen Ongoing improvement involves everyone
Top management Managers Workers
A culture of supporting quality improvement
more important than the use of any specific tools
KAIZEN
•KAIZEN Means change for better
KAI-Change ZEN-Better •KAIZEN movement in an organization signifies small improvements
made in the status –quo as a result of on going efforts •Once KAIZEN process sets in an organization, it leads to
empowerment and creativity starts functioning through every individual
•An organization using KAIZEN signals that the organization is committed to encouraging improvements made by its personnel as an “ongoing organizational
process”
4
A definition:
Destroy, in our minds, the concepts and techniques of manufacturing that we practice today.
Create a vision of what our production system and manufacturing techniques should be.
Carry out that Vision by breaking through the status quo.
Climate favors Kaizen Sharp increase in the costs of material,
energy, and labor Overcapacity of production facilities Increasing competitions Need to introduce new products more
rapidly Need to lower the breakeven point
Kaizen Culture A corporate culture in which everyone can
freely admit these problems A systematic and collaborative approach to
cross-functional problem-solving Internal, Next process is customer External, suppliers
Kaizen Culture A customer-driven strategy for
improvement Quality, cost, schedule, and delivery
requirements Emphasis on process
Result is not the only thing and everything Support and acknowledge people’s process-
oriented efforts for improvement
KAIZEN AND MANAGEMENT
Innovation
Kaizen
Maintenance
TopMgnt
MiddleMgnt Supervisor Worker
Hierarchy of KAIZEN involvement
Top Management
Be determined to introduce KAIZEN as a corporate strategy
Provide support and direction for KAIZEN by allocating resources
Establish policy for KAIZEN and cross-functional goals
Realize KAIZEN goals through policy deployment and audits
Build systems, procedures, and structure conducive to KAIZEN
Middle Management and StaffDeploy and implement KAIZEN goals as directed by top management through policy deployment and cross-functional managementUse KAIZEN in functional capabilitiesEstablish, maintain, and upgrade standardsMake employees KAIZEN-conscious through intensive training programsHelp employees develop skills and tools for problem solving
Supervisors
Use KAIZEN in functional rolesFormulate plans for KAIZEN and provide guidance to workersImprove communication with workers and sustain high moraleSupport small-group activities (such as quality circles) and the individual suggestion systemIntroduce discipline in the workshopProvide KAIZEN suggestions
Workers
Engage in KAIZEN through the suggestion system and small-group activities
Practice discipline in the workshop
Engage in continuous self-development to become better problem solvers
Enhance skills and job-performance expertise with cross-education
THE KAIZEN UMBRELLA
Customer orientation TQC (total quality
control) Robotics QC circles Suggestion system Automation Discipline in the
workplace TPM (total productive
maintenance)
Kamban Quality improvement Just-in-time Zero defects Small-group
activities Cooperative labor-
management relations
Productivity improvement
New-product development
HOW IS KAIZEN SYSTEM ORGANISED
Awareness Status assessment Planning for KAIZEN system A) organizational structure (CEO, KAIZEN committee, facilitator,
evaluators and the team) B) KAIZEN meetings C) KAIZEN board/bulletin D) KAIZEN implementation 1) Motivation 2) Human resources development 3) Improvement 4) Institutionalization
Japanese perceptions of job functions (1)
Top ManagementMiddle ManagementSupervisorsWorkers
Improvement Maintenanc
e
Innovation
Japanese perceptions of job functions (2)
Top ManagementMiddle ManagementSupervisorsWorkers
KAIZEN
Maintenance
Innovation-centered job functions
Maintenance
Western perceptions of job functions
Top ManagementMiddle ManagementSupervisorsWorkers
Innovation
Maintenance
Innovation
DEMING WHEEL
Design
ProductionResearch
Sales
FEATURES OF KAIZEN AND INNOVATION
KAIZEN Innovation
1. Effect Long-term and long-lastingbut undramatic
Short-term but dramatic
2. Pace Small steps Big steps
3. Timeframe Continuous and incremental Intermittent and non-incremental
4. Change Gradual and constant Abrupt and volatile
5. Involvement Everybody Select few “champions”
6. Approach Collectivism, group efforts,systems approach
Rugged individualism,individual ideas and efforts
7. Mode Maintenance andimprovement
Scrap and rebuild
8. Spark Conventional know-how andstate of the art
Technological break-throughs,new inventions, new theories
9. Practicalrequirements
Requires little investment butgreat effort to maintain it
Requires large investment butlittle effort to maintain it
10. Effort orientation People Technology
11. Evaluation criteria Process and efforts for betterresults
Results for profits
12. Advantage Works well in slow-growtheconomy
Better suited to fast-growtheconomy
KAIZEN InnovationJapan Strong WeakWest Weak Strong
Ideal pattern from innovation
Time
Actual pattern from innovation
Time
Innovation plus KAIZEN
Time
Innovation alone
Time
What should be (standard)
Innovation
Maintenance
What actually is
What actually is
Maintenance
What should be (standard)
New
standard
New
standardKAIZEN
Innovation
KAIZEN
Innovation
TOTAL MANUFACTURING CHAIN
Science Technology Design Production Market
Innovation
KAIZEN
Another comparison of Innovation and KAIZEN
Innovation KAIZEN
Creativity
Individualism
Specialist-oriented
Attention to great leaps
Technology-oriented
Information: closed, proprietary
Functional (specialist) orientation
Seek new technology
Line + staff
Limited feedback
Adaptability
Teamwork (systems approach)
Generalist-oriented
Attention to details
people-oriented
Information: open, shared
Cross-functional orientation
Build on existing technology
Cross-functional organization
Comprehensive feedback
WESTERN AND JAPANESE PRODUCT PERCEPTIONS
Technology Level
Preferred Process
Product
Western perceptions
Japanese perceptions
High technology
Technology-oriented innovation
Innovativeproduct
KAIZEN-orientedproduct
People-oriented +
KAIZEN
Low technology +KAIZEN
UPCOMING JAPANESE PRODUCT PERCEPTIONS
Technology Level
Preferred Process
Product
High technology
Technology-orientedinnovation
Technology-orientedKAIZEN
Technology-orientedinnovation
Technology-orientedinnovation
Technology-orientedinnovation
Low technology
KAIZEN SYSTEM WORKS ON THE PRINCIPLES OF
Empowerment •Zero (negligible) investment •Self-development •Listening •Waste elimination •Organizational support
EFFECTIVE KAIZENS
Eliminateany work that is dirty or dangerous •Modifyor simplifyany work that consumes significant time or
resources •Find anefficient wayof doing any work which is frequent or
common •Eliminate wastein any area –do not believe that waste does
not exist •Eliminate(at least reduce) waiting time. •Make the work better, easier, faster and safer using
MISERconcept (merge, improve, simplify, eliminate and reduce) •Improvethe work place by 5 S’s •Copyeffective KAIZEN