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snowflake | Kaizen Introduction, 01.04.15 1/23

Make everything as simple as possible but not simpler.Albert Einstein

We are what we repeatedly do. Excellence, therefore, is not an act, but a habit.Aristoteles

Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives.William A. Foster

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Presentation FlowIntroduction to Kaizen

Applications Theory

Applications @ snowflake

Implementation ConceptsPrinciples

Benefits

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Introduction to Kaizen

改善 = Kaizen = Change for better = Improvement

Focus on making continuous small improvements

Everybody is involved

Key wordsWWII, Toyota, Masaaki Imai

Shift unproductive to productive work = create value

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Key PrinciplesHeavy reliance on teamwork, in which everyone's opinion is valued and considered.

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Key PrinciplesWorkers also have strong personal discipline, and morale in companies must improve under Kaizen.

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Key Principles

Workers should also be confident about offering suggestions for improvement, even when a system appears to be functioning adequately.

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Key Principles Kaizen recognizes that there is always room for improvement.

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Key Principles

The system uses quality circles, worker groups who meet and work together to solve problems and come up with innovative changes.

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Implementation Concepts Quality Circles 5 S Kanban

Muda

7 Wastes

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5 S

Seiri (Sort): Tidiness, keeping only essential items, remove obstacles

Seiton (Set In Order): Orderliness, eliminate extra motion, repair, workflow: smooth

Seiso (Shine): Cleanliness, keep the workplace clean, clean to inspect

Seiketsu (Standardize): Standardize work practices

Shitsuke (Sustain): training, maintaining discipline and reviewing standards Look here for a more detailed list:

http://en.wikipedia.org/wiki/5S_%28methodology%29

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The Kaizen cycle = PDCA (Plan-Do-Check-Act) cycle

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Quality Circles

A quality circle is a (volunteer) group composed of employees, who are trained to identify, analyse and solve work-related problems and present their solutions to management.

This improves the performance of the organization, while also motivating and enriching the work of employees.

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KanbanKanban (meaning “signboard” or “billboard”) is a concept related to lean and just-in-time (JIT) production.

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7 Wastes

OverproductionFaster and more than needed

OverprocessingWhen is something complete? Pareto principle

WaitingSynchronization, people are idle

MotionSearch, Walk

TransportationMove material

InventoryWIP, Ressource planning

Defect/reworkQuality errors

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Benefits

Widely applicable:Can be used in both manufacturing and non-manufacturing environments.

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Benefits

Highly effective & results oriented:Kaizen events will generate quick results, measurable results, establish the baseline, and measure the change.

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Benefits

Higher operational efficiency: Reduces wastage, like inventory waste, time waste, workers motion.Improves space utilization and product quality.

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Benefits

A Learning Experience – Every member of a Kaizen Team will walk away from the event learning something new:Encourages big picture thinking.Results in higher employee morale and job satisfaction, and lower turn-over.

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Applications Theory

Applications @ snowflake

Mind the gap! Common pitfalls

“Kaizen” or “continuous improvement” should be a part of our everyday life

“Kaizen” or “continuous improvement” should be a part of our everyday life

Concept is simple but if properly applied can lead to significant efficiency improvements

UserVoiceKaizen on every hierarchy

Open feedback culture

Team, not management driven

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Mind the gap! Common pitfalls

Resistance of change

Lack of proper procedure to implement

Too much suggestion may lead to confusionand time wastage

Difficult to implement in large scale process,where analyzing requires a lot of time

Politics and blame games hinder changes

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PDCA Cycle:http://sarjeevansainbhi.webs.com/apps/photos/photo?photoid=136220067Mind the Gap: http://www.practicaldoc.ca/2015/01/23/mind-the-gap/Koto-in temple: http://regex.info/blog/2012-11-25/2150Some slides from http://de.slideshare.net/pratik207/kaizen-philosophy

Inspiration and Sources

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Questions?

dbrander@snowflake.ch