Kaizen - "SMALL is KILLER"

1. Group : 8

2. Contents
Introduction
Features of Kaizen
Five Elements
Implementation
Applicability of Kaizen
Mini Kaizen
Case Study

3. Introduction
 Masaaki Imai is known as
the developer of kaizen
 KAI means ‘change’ or
‘the action to correct’
ZEN means ‘good’

4. Features of Kaizen
 Widely applicable
 Highly effective & result
oriented
 A learning experience
 Term based & cross functional

5. Kaizen elements
 Teamwork: Kaizen has always been
a team effort, where synergies of
various members are harnessed
for increased productivity
 Increased efficiency: Kaizen
reduces cycle time & lowers
costs. This leads to
higher efficiency

6. Ctd...
 Improved morale & employee satisfaction: Since all
employees are involved in Kaizen process, there is a
high level of employee engagement
 Improved safety: Kaizen helps clean
up work areas, allowing better
control of equipment & processes
 The five-S framework: The Kaizen
method is often described in terms
of the “five-S framework.” The five-S framework
consists of the Japanese words “seiri” for tidiness,
“seiton” for order, “seiso” for clean, “seiketsu” for
standardization & “shitsuke” for discipline

7. Implementation Of
Kaizen1. Training
2. Project Selection
3. Team Selection
4. Value Stream Mapping
5. Process Mapping

8. Ctd...
6. Developing Baseline Data
7. Creating Spaghetti Charts
8. Conducting Time Study Analysis
9. Developing Continuous Improvement
10. Implementing Appropriate Changes

9. Applicability of Kaizen
MASAKI IMAI lists the following kaizen
duties for different level in Management
where as follows:
 TOP MANAGEMENT
 MIDDLE MANAGEMENT
 SUPERVISORS
 WORKERS

10. TOP MANAGEMENT
 Be determined to introduced kaizen as corporate
 Provide support and direction for kaizen by
allocating resources
MIDDLE MANAGEMENT
 Deploy & implement kaizen goals as directed by
top management
 Helps employees develop skills & tools for
problem solving

11. SUPERVISORS
 Improve communication with workers and sustain
high morale
 Support small group activities & the individual
suggestion system
WORKERS
 Engage in Kaizen through the suggestion system &
small group activities

12. Mini Kaizen
 Mini Kaizen is part of corporate culture
 Mini Kaizen, is aimed at increasing productivity,
quality, & worker satisfaction, all from a very
grassroots level
 Mini Kaizen helps to
reduce wastes, promotes
personal growth of
employees & the company,
provides guidance for
employees

13. Ctd...
 This methodology teaches that every employee
should be encouraged to come up with new &
innovative ideas, no matter how big or small they
are
 This change should be
done by the employee,
with a minimal investment
of time
 Quick and Easy Kaizen Ex. 1 - ouTube.flv

14. Ctd...
 Three Key Characteristics
 Permanent method changes
 Continuous flow of small ideas
 Immediate local implementation

15. Case Study:
Toyota

16. Ctd...
 Toyota Motor Company was one of the first
Japanese businesses to implement Kaizen. After
World War II, Kaizen was adopted by several
Japanese companies to help rebuild. Since this
time, kaizen has become so successful, that it has
spread to several businesses throughout the world
 Toyota benchmarks
itself on efficiency. It
trains recruits in 'muscle
memory', so that their
hands work with unfailing precision

17. Ctd...
 The result: an Etios, Etios Liva
or Corolla rolls off the
assembly line in Toyota's
Plant No. 2 in Bidadi,
Karnataka, every 119 seconds,
& an Innova or Fortuner in Plant No. 1 every 162
seconds. In 16.5 hours of operation in a day, the two
plants produce a total of 744 vehicles
 After a plant reaches peak efficiency, the
management reduces the number of workers
slightly, so that the efficiency ratio falls. Then it
introduces kaizen to return to the earlier level

18. Ctd...
 An industry expert says that the Innova's steel yield
ratio in India is the best in the world
 Toyota India ranks number one globally in the
shipping quality audit, an annual exercise carried
out at Toyota facilities worldwide
 The audit focuses on the
quality of vehicles before
they are dispatched to
market

19. Presented By,
Ankita Bondre
Gauri Dhalwalkar
Nikita Lakhan
Priya Dolas
Soniya Raikar
Prakhar Jain