Sensei Masaaki Imai

KAIZEN® BASICS

2009 Kaizen Institute

W
Welcome !

KAIZEN® Sensitization Session

for Trainees @ MBA 1st Year,
SCMLD
1 May 09

2009 Kaizen Institute

= KAI = CHANGE

= ZEN = GOOD
(FOR THE BETTER)

= KAIZEN =
CONTINUAL IMPROVEMENT
 KAIZEN Journey
A S

C D

A P

C D P: Plan
D: Do
C:Check
A S A:Act

C D S: Standardize
D: Do
C:Check
A:Act
2009 Kaizen Institute
 KAIZEN is: Focused Improvement.
[Improvement is different from Focused
Improvement] Focused
Improvement Improvement

KAIZEN

Paper does not

burn in sunlight

FocusedPaperimprovement
burns concentrates
Improvement is like sunlight: the energy:
• Lot of energy, but dispersed (wasted) • Little energy, but concentrated
• Small improvements and aligned
• Slow progress. • Enables significant (large)
improvements
• Small time required
2009•Kaizen
Rapid progress
Institute
 Isn’t KAIZEN supposed
to be
small improvements?
Kaizen is small change
that leads to
Large Improvement

KAIZEN: Succession of
small changes (steps)
that result in
large improvement
2009 Kaizen Institute
KAIZEN is:
DENTIFYING STRATEGICALLY IMPORTANT AREA AND IMPROVING THER

UTILITY COST PER CAR

100.0%
OTHERS
8%

POWER Shop C
80.0%
20%
C
O
S 72% Shop B
60.0%
T 30%

I 40.0%
N FUEL Shop A
AIR
% 20.0% 13%STEAM 42%
WATER KAIZEN (FI) Project
9% 2009 Kaizen Institute should focus here
IZEN is: making Sustainable Improvements
Improvement with
involvement
gives sustainability

Study
machines & methods
Involve people in
improvement process

Involve managers in
improvement process

S:
Managers must A S Standardize
sustain improvements by
practicing SDCA cycle
D: Do
C D C:Check
A:Act
2009 Kaizen Institute
 What really is KAIZEN®?

Kaizen is process improvement:

• which is significant (large)
• done in strategically important areas
• speedily
• in sustainable manner
using data, not opinion
using tools & techniques – not anyhow

2009 Kaizen Institute

GEMBA

GEM + BA
means means

Real + Place

GEMBA is where :
•Real Work Is Done
•Value Is Created
•Problem Is Solved

2009 Kaizen Institute

 Organization for Kaizen

Customer
Gem
Customer
ba
Organiza
expectations satisfaction
tion
to
support

2009 Kaizen Institute

PDCA

Act Plan

Check Do

The Improvement Cycle
2009 Kaizen Institute
Golden Rules of Gemba Management

1.Go to gemba
2.Check gembutsu, collect data
3.Take temporary countermeasure
on the spot
4.Diagnose Root Cause
5.Standardize to prevent recurrence

2009 Kaizen Institute

 MUDA

Elements of process- that add time, effort, cost,

but no value

Things to Remember about Waste:

•MUDA is really a symptom rather than a root cause
of the problem
•MUDA points to problems within the system
(At both process & value stream levels)

2009 Kaizen Institute

Essence of KAIZEN®
Philosophy
Kaizen focuses on Muda
-

2009 Kaizen Institute

Essence of KAIZEN®
Philosophy
Muda
Kaizen acts on-

Don’t attack; it Convention

is useful ! Attack first chases this !
2009 Kaizen Institute
 7 Types of Muda In Processing
TYPES EXAMPLES
1) Defects Scrap, rework, replacement , inspection
2) Waiting Stock-outs, lot processing delays, equipment
downtime, capacity bottlenecks
3) Processing Unnecessary or incorrect processing
4) Manufacturing the Items in anticipation, for which
Overproduction there are no orders, no requirement from internal /
external customers
5) Motion Human motions that are unnecessary or straining
6) Inventory Excess - Raw Material or WIP or Finished Goods
7) Transport Carrying WIP to long distances, inefficient transport

2009 Kaizen Institute

2009 Kaizen Institute
Mura - Inconsistencies

• Happens only
sometimes? Mura!
• Happens to only some
people? Mura!
• Happens only some
places? Mura!
-Ask “Why” five times
-Use diagnostic method
like Kepner-Tregoe

2009 Kaizen Institute

Mura - Inconsistencies

EXAMPLE

All Quality Problems are examples of MURA

2009 Kaizen Institute

Muri - Physical
Strain
• Bend to work? Muri !

• Noisy? Muri !
• Polluted air? Muri !

• Vibrating machine?
Muri !

2009 Kaizen Institute

Kaizen Action
Sequence
Always I. R. E. :
MUDA First

MURA Next

MURI Last

2009 Kaizen Institute

2009 Kaizen Institute