Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Kai :- Change
Zen :- For Betterment
To improve productivity.
To reduce cost
To improve quality.
2. Improvement of safety.
MUDA Related to Manpower
Monitoring (machines)
Walking & Moving (layout)
Conveyance (materials)
Searching
Irresolution (methods)
Handling (products)
Motion
Reworking
Idling
MUDA Related to Machines &
Equipments
Space and transportation
Efficiency
Leakage of oil
Minor stoppage
Cleaning (Prevention)
Leakage of air & energy
Lights on
MUDA Related to Means
Congestion (bottleneck process)
Inventories
Idling of machines
Set up of machines
Adjustments
Wrapping and unwrapping
MUDA Related to Quality
Control
Production of defectives
Reworking
Fool proofing of automated machines
Absence of standards
Flaws caused by conveyance
Inspections
MUDA Related to Materials. &
Parts
Clamping with bolts
Number of parts
Deburring operations
Heavy weight materials. & parts
Expensive materials
Scrap slug
Improvement of Safety
Danger at rotating parts
Danger of being caught in moving machines
Danger of being cut
Danger of fall
Danger of falling objects
Danger of collision
Danger related to handling
Danger at restarting the machine
Improvement of Safety
Danger of electric shock
Danger of accidents by toxic substances
Danger of explosion
Danger of high temperature
Danger related to work done by inexperienced
persons.
Danger from the absence of an established method
of use.
Danger from absence of dangerous zone signs.
Kaizen
Question to Generate Kaizen
Can I reduce the strainIdeas
in the operation?
Can this improvement be applied else where?
Is there an alternative way to do it?
Can this be reduced?
Can this be increased?
How can I identify the defect at source?
What are the non-value adding operations?
Can this be done in a faster, cheaper, safer, & easier
way?
Can I reduce the variations?
Kaizen
Seven Tools to Identify & Solve the Problem
Causes and effect diagram.
Check sheet
Pareto chart
Flow chart
Brain storming
Histogram
Control chart
Kaizen
Ask why 5 times & then how?
Q.1 Why are you throwing saw dust on the floor?
A. “Because the floor is slippery and unsafe.”
Q.2 Why is it slippery and unsafe?
A. “Because there is oil on it.”
Q.3 Why is there oil on it?
A. “Because the machine is dripping.
Q.4 Why is it dripping?
A. “Because oil is leaking from the oil coupling.”
Q.5 Why is it leaking?
A. “Because the rubber lining inside the coupling is worn
out.”
Kaizen
Ishikawa ( fishbone) diagram
Diagram developed by Professor Kaoru
Ishikawa to show, causes (process) & the effect
(result).
One of the basic tool of problem solving.
Cause Effect
Kaizen
Practical part of Kaizen
Form a small group of 5 to 7 people.
Assign specific area for identification of Kaizen idea
Use seven tools to identify root cause and to solve the
problem.
Find out counter measure.
Implement Kaizen idea.
Assess the results.
Decide horizontal deployment.
Write the details in Kaizen-sheet.
Asses the knowledge of participants through assessment
feedback form.
Kaizen
Kaizen sheet
Please see the photograph of
Kaizen sheet board.
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1. Whichof thefollow ing descriptionbest suitstheKaize
nmoveme
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A. Zenindustrial im provem ents
B. Zerointe nsityinitiative
C. Zeroinve stm entim provem ent
D. All of theabove
E. Noneof theabove.
2. Kaize
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A. Toplinem anagem ent
B . Middlelinem anagers
C. Front linem anagem ent
D . Noneof theabove
E. All of theabove