1. Presentation
on
"Kaizen- Implementation”
‘An Idea can change the way to work’
Date:-

2. Definition of Kaizen:
“A system of continuous Improvement in which instances of muda(waste) are
eliminated one by one at minimal cost. This is performed by all employees rather
than by specialists.”
Kaizen is process improvement which is significant, done in strategically
important areas, speedily , in sustainable manner by using data, not
opinion. & using tools & tech.. not anyhow.
Basically kaizen is for small improvements, but carried out on a
continual basis & involve all people in the organization.
The principle behind is that a very large no. of small improvement are
more effective in an organizational environment than a few
improvements of large value.
By using a detailed & through procedure we eliminate losses in a
systematic method using various kaizen tools. This activities are not
required to production area only & can be implemented in admin areas
also.
‘An Idea can change the way to work’

3. Definition of waste :
“Waste is any step or action in a process that is not required to complete a
process (called “Non Value-Adding”) successfully. When Waste is removed,
only the steps that are required (called “Value-Adding”) to deliver a
satisfactory product or service to the customer remain in the process.”
Type of wastes :
‘An Idea can change the way to work’

4. Kaizen Umbrella Concepts:
‘An Idea can change the way to work’

5. Get rid of all old (false) assumptions.
Don’t look for excuses , look for ways to make it happen…
Don’t worry about being perfect.
Even if you only get it half right “ start now”!
It does not cost money to do kaizen.
If something is wrong “ fix it now”.
Good ideas flow when the going gets tough.
Ask “why” five times –get to the root.
Look for wisdom from 10 people rather than one.
Never stop doing Kaizen.
Kaizen ( Improvement) principles:
‘An Idea can change the way to work’

6. Kaizen Target:
“Achieve & sustain zero losses with respect to minor stops,
measurement & adjustments, defects & unavailable downtimes.”
Kaizen Policy:
Practice concepts of zero losses in every sphere of activity.
Relentless pursuit to achieve cost reduction targets in all resources.
Relentless pursuit to improve overall plant equipment effectiveness.
Extensive use of P.M. analysis as a tool for eliminating losses.
Focus of easy handling of operators.
‘An Idea can change the way to work’

7. of Kaizen:
Kaizen involves every employee in making change in most cases small,
incremental changes.
It focuses on identifying problems at their source, solving them at their source , &
changing standards to ensure the problems stays solved.
Kaizen reduces waste in areas such as inventory , waiting times, transportation ,
worker motion , employee skills, over production ,excess quality & in processes.
Kaizen improves space utilization , product quality , use of capital ,
communications, production capacity & employee retention.
Kaizen provides immediate results. Instead of focusing on large , Capital
Intensive improvements, Kaizen focuses on creative investments that continually
solve large numbers of small problems.
‘An Idea can change the way to work’

8. 1. Defects – Products or services that are out of specification that require
resources to correct.
2. Overproduction – Producing too much of a product before it is ready to be sold.
3. Waiting – Waiting for the previous step in the process to complete.
4. Non-Utilized Talent - Employees that are not effectively engaged in the process
5. Transportation – Transporting items or information that is not required to
perform the process from one location to another.
6. Inventory – Inventory or information that is sitting idle (not being processed).
7. Motion – People, information or equipment making unnecessary motion due to
workspace layout, ergonomic issues or searching for misplaced items.
8. Extra Processing – Performing any activity that is not necessary to produce a
functioning product or service.
Type of wastes :
‘An Idea can change the way to work’

9. Waste Definition Office Example Manufacturing Example
Defect
Work that contains errors
or lacks something
necessary
• Incorrect information being shared
• Data entry errors
• Forwarding incomplete documents
• Scrap
• Rework
• Missing parts
Overproduction
Producing more materials
or information than
customer demand
• Creating reports no one reads/needs
• Making extra copies
• Providing more information than needed
• Producing more products than demand
• Batch process resulting in extra output
• Having a “push” production system
Waiting
Idle time created when
material, information,
people or equipment is
not ready
• Ineffective meetings
• Waiting for meetings to start
• Files awaiting signatures/approvals
• Waiting for tools, parts, information
• Broken machines waiting to be fixed
• Raw materials not ready
Not Utilizing Talent
Not, or under, utilizing
the talent of employees
• Insufficient training
• High absenteeism and turnover
• Inadequate performance
• Employing people in the wrong position
• Not fully training employees
• Missing improvements by failing to listen to employees
Transportation
Movement of materials
or information that does
not add value
• Hand carrying paper to the next process
• Delivering unneeded documents
• Going to get signatures
• Moving products around before shipping
• Moving product from different workstations
• Moving inventory around to take stock
Inventory
Excess materials on hand
that the customers or
employees do not need
right now
• Purchasing excessive office supplies
• Searching for computer files
• Obsolete files or office equipment
• More finished products than demand
• Extra materials taking up work space
• Broken machines sitting around
Motion
Movement of people that
does not add value
• Searching for files
• Walking/reaching to get materials
• Sifting through inventory to find what is needed
• Reaching to make adjustments
• Walking to get a tool multiple times
• Repetitive movements that could overwork/injure an employee
Extra Processing
Efforts that do not
provide value from the
customer's perspective
• Unnecessary signatures on a document
• Making more copies of a document than will be
needed
• Saving multiple copies of the same file in multiple
locations
• Adding unneeded value to a product
• Using a more high-tech machine than needed
• Extra steps to correct avoidable mistakes
‘An Idea can change the way to work’

10. Example :
Before Waste is removed, processes are often scattered, which can negatively
affect your customers:
Before Waste is removed in a kitchen (Sandwich making process example).
‘An Idea can change the way to work’

11. Example :
After Waste is removed in a kitchen (Sandwich making process example).
After Waste is removed, processes are more streamlined, resulting in more
satisfied customers. You’ll also save your organization time and money:
‘An Idea can change the way to work’

12. Question & Answer Session :-
‘An Idea can change the way to work’

13. Prepared By:-
Pranav B.
Gujjar
‘An Idea can change the way to work’