Japanease management technique Kaizen and its impletenttion in Toyota production system (TPS)

1. KAIZEN
SYED MOHAMMAD HASSAN
NOUKHAIZ ASLAM
AWAIS AHMED
ABUZAR KHAN

2. 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.

3. PDCA MODEL
 System for executing Kaizen.
 Four step management model.
 The acronym stands for
 Plan
 Do
 Check
 Act

4. KAIZEN'S ADVANTAGES
 Reduces waste
 Improves employee utilization
 Improves production
 Reduces completion cycle time
 Higher job satisfaction

5. 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

6. 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

7. 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.

8. TECHNIQUES USED IN TPS
 The Production Cell
 Just in Time (JIT)
 Total productive maintenance
 5s
 Single Piece Flow
 Quality Control Circle
 Waste

9. 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.

10. KAIZEN PRODUCTION EFFICIENCY MANAGEMENT
 Toyota production line “Shôjinka”.
 Group leaders are in charge of reducing the cycle time.
 Increasing production efficiency.
 Lowering production cost.

11. 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.

12. 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.

13. PIT FALLS IN KAIZEN
 Resistance to change.
 Lack of proper procedure to implement.
 Too much suggestion may lead to confusion and time
wastage.

14. RECOMMENDATIONS
 Employees consent and views must be taken into
account.
 Use of well defined procedures.
 Well defined procedures must be observed.

15. THANK YOU