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Kaizen

This document discusses the concepts of Kaizen and Gemba. Kaizen means continuous improvement, while Gemba refers to the real place where value-adding work occurs. There are five principles for practicing Kaizen in Gemba: understanding the situation through direct observation, analyzing the root causes of issues, developing countermeasures through experimentation, standardizing successful processes, and spreading improvements. Managers are encouraged to solve problems at Gemba using low-cost, commonsense approaches rather than complex tools. Benefits of practicing Kaizen include reducing waste, improving quality and productivity, and increasing employee morale.

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KAIZEN GEMBA
CONTENTS • • • • • • • BASIC CONCEPT KAIZEN TOOLS GEMBA 5 GEMBA PRINCIPLES LOW COST APPROACH GROUND RULES BENEFITS OF KAIZEN GEMBA
Kaizen Gemba The concept of Kaizen was given by Masaki Imai who was more a practitioner rather than a philosopher. Kaizen means continuous improvement. Gemba is a Japanese word meaning 'real place,‘ where the real action takes place.
Who does KAIZEN ? Why ? 5 http://www.kaizen.com/
KAIZEN TOOLS • • • • • Quality Circle PDCA 5S Kanban-Lean Manufacturing-Just In Time Poka Yoke-Mistake Proofing-Zero Quality Control by humans.
• So,we all are well aware about various Kaizen Tools which when applied will help to achieve quality. • But friends…..the question is – Where to apply these tools??????
KAIZEN GEMBA • The answer is- Gemba. • Where can the value addition be done?? 1. While developing a product. 2. While producing/manufacturing. 3. While selling. • Management gives more importance to 1 & 3. • Customer Point of View-2 is more important. • For balance-Gemba required.
5 GEMBA PRINCIPLES
1
2
Gembutsu
3
Countermeasures
4
ROOT CAUSE
5
Gemba KAIZEN - Low cost approach In order to solve problems found in gemba, today’s managers often try to apply sophisticated tools and technologies to deal with problems that can be solved with a commonsense, low-cost approach.
2 APPROACHES
Ground rules for practicing Kaizen in gemba: 1. Housekeeping, 2. Muda elimination. 3. Standardization.
1. Housekeeping Housekeeping is an indispensable ingredient of good management. Through good housekeeping, employees acquire and practice self-discipline. Employees without selfdisciplines make it difficult to provide products or services of good quality to the customer.
5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized. 23
2. Muda elimination In Japanese, the word muda means waste. Any activity that does not add value is muda. People in gemba either add value or do not add value. This is also true for other resources, such as machines and materials. Muda elimination can be the most costeffective way of improving productivity and reducing operating costs.
3. Standardization • Standards may be defined as the best way to do the job • Products or services are created as a result of a series of processes. Certain standard must be maintained at each process in order to assure quality. • Standards also can prevent recurrence of the same problem 25
Benefits of kaizen  Kaizen Reduces Waste like inventory waste, time waste, workers motion  Kaizen Improves space utilization, product quality  Results in higher employee moral and job satisfaction, and lower turnover.  Toyota is well-known as one of the leaders in using Kaizen. In 1999 at one U.S. plant, 7,000 Toyota employees submitted over 75,000 suggestions, of which 99% were implemented. 26