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Kaizen Training PPT.ppt
- 1. 8/26/2023 1 “A Kaizen a day keeps MUDA away” Kaizen Training Programme
- 2. Are these equations same ? • Profit = Selling Price – Cost Price • Selling Price = Cost Price + Profit • Cost Price = Selling price – Profit No Yes May Be
- 3. Why Kaizen? The prime goal of any organization is to earn the profit. Old Concept Price = Manufacturing cost + Profit Current Concept Profit = Price – M.Cost
- 4. Kaizen Kaizen is the Japanese philosophy of continuous improvement by all the employees in an organization so that they perform their tasks a little better each day. It is a never ending journey centered on the concept of starting new each day with the principle that the methods can always be improved. Kaizen
- 5. The Japanese description of the effectiveness of a suggestion is expressed as: “It is better for one hundred people to take one step than for one person to take a hundred’ Suggestion Suggestion is an idea or proposal for any improvement.
- 6. Kaizen “Kai” in Japanese means “Change” and “Zen” means good. The literary meaning of Kaizen is “change for good” KAI ZEN KAI + ZEN = KAIZEN
- 7. Kaizen The road to excellence is not the major break-through , but small continuous improvements which result in real cost savings, higher quality or better productivity. The latest developments in Japan advocate the idea of taking small incremental Risks along with small continuous improvements to win . Kaizen
- 8. Kaizen : Foundations Employee empowerment Self discipline Recognition
- 10. How to Create a Kaizen ? 10 Identify the needed Work Then observe all the elemental acts Identify which act turns into intended task Now you have identified real work Think of those other acts – Why they are required? Think! how this activity can be eliminated – Alternate method Idea for Kaizen created
- 11. Everyone must be involved in kaizen
- 12. Suggestion/Kaizen Culture Organization Structure- Steering Committee, Facilitator , Suggestion Committee, Coordinator. Suggestion policy: Award /Reward Criteria, Frequency of Award. Suggestion Form & Suggestion box. Training : Awareness on Suggestion Policy Suggestion collection and recording system. Implementation of valid Suggestions : Kaizen Motivation : Recognition and award. Effectiveness : Suggestion/ Employee/Month, Kaizen/Employee/Month
- 15. Gemba Kaizen
- 16. Genchi Go to the spot Genbutsu See the actual problem/situation Genjitsu Take necessary action 3 G Japanese strongly believe in 3G concept. 3G helps in correct decision making basis on actual condition.
- 17. Three ground rules for practicing Kaizen in gemba: 3 ground rules for practicing Kaizen in Gemba are: - 1. Housekeeping-5S 2. Standardization. 2. Muda, Mura and Muri elimination-3R,3M, 8Waste
- 18. A work place where the 5S is not maintained , any sort of improvement is not possible. Basic kaizen begins with 5S
- 21. Know the work place and search out waste. •Kaizen begins with finding out problems and waste at the work place. •Every operation needs to be constantly scrutinized and the question should always be asked “ IS THERE A BETTER WAY?
- 22. Reduce - Reduction in consumption of resources Re-use - Re-using things wherever possible Recycle - Recycling the waste so that it can be used again 3 R The idea is to conserve the resources (Man, Machine, Material, Energy, Environment, Time) used in manufacturing …… 22
- 23. Keep Your Eye on Scrap Example: metal sheet with six stamped holes (product) Workers ask, "What was in those holes?" Most people saw scrap for remelting and reuse. Other people saw radiator caps. Pressing two disks made a very strong radiator cap. 23
- 24. Re-Use COMMENTS : Left over fiber is scraped to waste yard COMMENTS : Left over fiber is used in Bolero under layer Title: Reuse of Left Over Fiber in Mix Color Fabric
- 25. COMMENTS : Left over side cutting moved to the scrap yard. COMMENTS : Left over side cutting reopened by trim opener machine & moved to mix master & reused as raw material. Recycle Title: Reopening Of Side Cutting Online By Trim Opener MC & Reusing It
- 26. 3 Wastes MUDA WASTE MURA INCONSISTENCY/ UNEVENNESS/ IRREGULARITY MURI OVERBURDEN/ INCONVENIENCE/ STRAIN Eliminate or minimize these three M’s in the manufacturing process
- 27. What is 3 M ? 1. What is MUDA? (waste) Using a two ton truck to transport a one ton load is waste. Are there any instances of such waste in your own work? 2. What is MURI? (overburden / inconvenience) Using a 0.5 ton truck to transport a one ton load is overburden. Are there any instances of such overburden in your work? 3. What is MURA? (unevenness/ irregularity) Moving a one ton load with one ton truck one time, then with 0.5 ton or 2 ton truck another time , or everyone using his/her own preferred methods for a particular job, are examples of unevenness which might be experienced in our work.
- 28. 28 Defining Value and Waste • Defining value - an item or feature for which a customer willing to pay. (Every thing else : Waste) • Waste - activities that consume time, resource and/or space but do not add value. • Solution : Lean : Production of product to meet demand on daily basis with minimum lead time & non value added activities eliminated or minimized
- 29. AVERAGE CONTRIBUTION 35 % 40 % 25 % Saleable jobs Not Saleable but necessary Waste
- 31. Space Saving Position change of lubricating oil tank which was projecting out Are there any equipment accessories projecting out ? Try to shift these to suitable locations .
- 32. Space Saving Placing hydraulic tank on top of the parts shelf Do you find any equipment accessories projecting out which can be placed on top of some other item, thus saving space ?
- 33. Space Saving Placement of electric fans Let the fans be mounted on pillars, wall or ceiling . This will also ensure safety .
- 34. Space Saving Effective use of space below working table, etc... Is there any vacant space below working table, roller conveyor, etc... which can be utilized effectively ?
- 36. Operation Improvement Improvement in handling of heavy bin Can you simplify the way in which heavy objects are being handled ?
- 37. Operation Improvement Simplification of bin replacement Are there any handling operations in which use of forklift can be eliminated by changeover to roller trolleys ?
- 38. Elimination of use of hammer Identify areas where hammering operation can be eliminated .
- 39. Operation Improvement Improvement in working posture Look for operations where operator is working in uncomfortable posture. Implement Kaizens to rectify these .
- 40. Operation Improvement Reduction in man movement by changing layout Identify areas where distance between 2 workstations can be reduced .
- 41. Reduction in man movement by change in location of facilities. Identify wasteful man movements in various processes and try to eliminate the same .
- 42. Operation Improvement Reduction in man movement by changing location of parts storage Is it possible to reduce man movement by changing work position, location of material storage or material flow ?
- 43. Operation Improvement Visual control - Opening & closing of air valve Visual control is important in reducing errors & improving efficiency .
- 44. ENERGY SAVING
- 45. Energy Saving Height change of fluorescent lamp Illuminance is inversely proportional to the square of distance . So place the lamp closer to operator .
- 46. Energy Saving Change in position of light Change the position of lamps so that shadow of operator does not affect his work .
- 47. Energy Saving Fixing of tube light on machine Wherever possible , fix tube light on equipment itself .
- 48. Energy Saving Lighting in material storage area Review lighting arrangement in material storage area . Provide common switch so that lights are on only when someone is working in these areas
- 49. Energy Saving Use of gravity flow Eliminate use of motorized conveyors wherever flow of material using gravity force is possible .
- 50. WEIGHT REDUCTION
- 51. Weight Reduction - Compactness Weight reduction of balancer Reduce weight of balancer so that it is easier to handle .
- 53. Material Flow Improvement Reduction in multiple handling Material handling does not add value to final product . Try to reduce material handling.
- 54. Material Flow Improvement Direct supply of material to line Introduce direct supply of material to line . Eliminate intermediate storage .
- 55. Material Flow Improvement Reduction in frequency of transportation Implement Kaizens to improve capacity of bins and trolleys so that higher number of components can be carried at one time.
- 56. Material Flow Improvement Increase in storage capacity Is it possible to change from one layer storage to double layer storage ?
- 57. Material Flow Improvement Improvement in handling efficiency Is it possible to improve handling efficiency by supplying parts in dismantled condition ?
- 59. Quality Improvement Prevention of coolant spillage Identify areas where coolant or oil spillage is taking place and implement suitable kaizens to avoid these .
- 60. Quality Improvement Improvement to avoid mixing of parts To ensure quality, it is important to ensure only one type of part in one container.
- 61. 61 8/26/2023 Thank you and all the best Air show Boat race Parajump “It is only when people bring their strength together that we can weave a unique and beautiful world”