What is kaizen?

Kaizen is a Japanese term meaning "Continuous Improvement".

Kaizen is

• Philosophical Approach• Common Sense Approach

There are two essential elements that make up KAIZEN:

* improvement/change for the better; and* ongoing/continuity.

Introduction to Kaizen (Different thoughts)

---Kaizen is continuous improvement------Kaizen is employee involvement---------Kaizen requires a cultural change

The purpose of Kaizen is to improve the quality continuously by eliminating wastes in terms of time, money, rework, etc. It involves everyone from Manager level to worker level. The key aspect of KAIZEN is that it is an on-going, never-ending improvement process.

"KAIZEN means improvement. Moreover, KAIZEN means continuing improvement in personal life, home life, social life, and working life. When applied to the workplace, KAIZEN means continuing improvement involving everyone - managers and workers alike". KAIZEN recognizes that improvements can be small or large. Many small improvements can make a big change.

People at all levels of an organization can participate in kaizen, from the CEO down, it is best if everyone is involved. The format for kaizen can be individual, suggestion system, small group, or large group.Kaizen is a daily activity where the purpose goes beyond easy productivity improvements. It is also a process that, when done correctly, cultivates the workplace, eliminates hard work and teaches people how to carry out a new way of thinking about there job by using new methods and showing them how to learn to see and eliminate waste.

KAIZEN is thus a (relatively) low cost, simple, team-based approach. Team are trained in the techniques and tools of KAIZEN. They then brainstorm improvement ideas and vote on them for priority action. They then create an action/implementation plan which is submitted to management for approval. Assuming it is approved, the team then sets about implementation (with professional help if appropriate). The team then meets weekly to review progress, identify/overcome barriers, celebrate successes, and document the resulting changed processes.

Kaizen has three main principles

• Consider the process and the results!• The need to look at the entire process of the job at hand and to evaluate the job as to the best way to get the job done. • Kaizen must be approached in such a way that no one is blamed and that the best process is put into place.

Kaizen is only one of many ways to create a good place and also an effect place for the company to make money and have less wasted time.5S it is a very effective Japanese program and together Kaizen and 5S are very effective when used correctly to create a safe and effective work place.

5S

5S is a technique for organizing a workplace, especially a shared workplace like a shop floor or an office space. It's sometimes referred to as a housekeeping method but this description can be misleading because organizing a workplace goes beyond housekeeping. The key targets of 5S are workplace morale and efficiency. The point of 5S is, to assign everything a location, time is not wasted by looking for items. It is quickly apparent when something is missing from its designated location. 5S advocates believe the benefits of this style comes from deciding what should be kept, where it should be kept, and how it should be stored.

A very important part of 5S and "standardized cleanup" is Seiton. The key concept here is to order items or activities in a manner to promote work flow. For example, tools should be kept at the point of use, workers should not have to repetitively bend to access materials, and flow paths can be altered to improve efficiency.

A term commonly used in Japan is gemba kaizen. It is an expression that conveys commitment to continuous improvement of practices and processes as a business philosophy. Translated to English "gemba" means shop floor and "kaizen" means continuous improvement. This certificate prepares students/workers to actively participate in implementing ongoing, world-class manufacturing activities necessary to keep their company globally competitive now and into the future.

One of the more attractive features of gemba kaizen as a management philosophy is its independence from technology, complex procedures, or equipment, because gemba kaizen techniques focus on techniques like total quality management, just-in-time, total product maintenance, and visual management to deliver maximum quality. For some companies, gemba kaizen has become a leading philosophy for implementing "lean thinking" into their processes and products. The result has been elimination of waste (in terms of materials, effort, money, time, etc.) and an improvement in fiscal performance. Not surprisingly, gemba kaizen's approaches to eliminating waste are also one of the easiest and least costly steps to take in improving environmental performance.

In Japanese, the definition of Kaizen is "improvement" and particularly, "Continuous Improvement"-- slow, incremental but constant.

Different styles of change

1. Small change (KAIZEN)

By individual effort, a better way of preceding a job is considered. (Idea creation)

2. Medium change (Small group activities)

By group effort, a better way is proposed by following predetermined steps(or rule).

3. Big change (Innovation)

By investments in new technology or equipment, dramatic

Large-Scale Vs. Small-Scale Improvement

Large scale improvement is attractive. It promises quantum jumps in productivity, quality and effectiveness. However, it is difficult to implement because it affects many areas, people and processes. The design must be near-perfect because failure courts disaster. The risks and difficulties work against large-scale improvements.

Small-scale improvements are easier and faster. The risks are low because they generally have limited effect. However, the accumulated effect is often greater than a single large improvement.

Here is the sequence of events for a Quick & Easy Kaizen

1. An employee identifies a problem, waste, defect or something not working. He/she writes it down.

2. Employee later develops an improvement idea and goes to immediate supervisor. 3. Supervisor reviews it and encourages immediate action. 4. The idea is implemented. 5. The idea is written up on a simple form in less than three minutes. 6. Supervisor posts the form to stimulate others and recognize the accomplishment.

Quick and Easy Kaizen Benefits

Mini kaizen empowers employees, enriches the work experience and brings out the best in every person. It Improves quality, safety, cost structures, environments, throughput and customer service.

Quick and Easy Kaizen  (or Mini-Kaizen) is aimed at increasing productivity, quality, and worker satisfaction, all from a very grassroots level. Every company employee is encouraged to come up with ideas – however small – that could improve his/her particular job activity, job environment or any company process for that matter. The employees are also encouraged to implement their ideas as small changes can be done by the worker him or herself with very little investment of time.

Quick and easy Kaizen helps eliminate or reduce wastes, promotes personal growth of employees and the company, provides guidance for employees, and serves as a barometer of leadership. Each kaizen may be small, but the cumulative effect is tremendous.

Kaizen Activities for Increased Profits

Four Measures for Increased ProfitsWhen companies aim to improve their profits, the following four methods are effective:

1. Raise unit prices for the sales of goods and services2. Lower unit prices for the purchase of materials: input3. Increase the amount of output4. Produce goods and services with lower costs through Kaizen activities

The first method, raising unit sales prices, often brings many difficulties. This is because products on the market are already priced at their market prices, and the consumers will buy products and services from the competition if unit sales prices are raised. It is clear that a price increase will result in a loss of a certain share of the market. Other than the cases where the product enjoys a company monopoly of the market, or there is some understandable motivation such as the oil shock, it is difficult to carry out price increases.

The second method, lowering the purchase prices of materials, will earn charges of difficulty from those in charge of purchasing because they are always putting great effort into buying materials as cheaply as possible.

The third method, increasing the amount of output by increasing men and facilities, is indeed a good idea. If the goods and services are bought by consumers, the company profits will increase. However, if surplus output remain as stock, or are disposed of as waste, profits will not increase. Losses requiring extra materials or manpower will result instead.

The Effects of Kaizen ActivitiesThe most practical measures for improving profits, which are carried out successfully in many companies, are found in the fourth method, Kaizen activities. Not all Kaizen activities can bring about cost reductions, but in many cases, cost-cutting is achieved if the activities target the elimination of waste. It is true that among those four measures, the economic effects of Kaizen activities are comparatively small when compared to the other three measures. Kaizen activities are characterized as: little and many makes a pile.

Who has the best knowledge to reduce costs?

Standard Costing

Managers and engineers develop Standards.

Kaizen Costing

Workers are closest to the process and thus know best.

kaizen is a Japanese tradition which is now used internationally, modified by each culture to best suit their own business environments. A literal translation of kaizen could be "to become good through change". At its most basic the concept of kaizen is one of restructuring and organizing every aspect of a system to ensure it remains at peak efficiency.

Kaizen is founded upon five primary elements:

Quality Circles: Groups which meet to discuss quality levels concerning all aspects ……of a company's running.

Improved Morale: Strong morale amongst the workforce is a crucial step to …....achieving long-term efficiency and productivity, and kaizen sets it as a ……foundational task to keep constant contact with employee morale.

Teamwork: A strong company is a company that pulls together every step of the …….way. Kaizen aims to help employees and management look at themselves as …….members of a team, rather than competitors.

Personal Discipline: A team cannot succeed without each member of the team …….being strong in themselves. A commitment to personal discipline by each …….employee ensures that the team will remain strong.

Suggestions for Improvement: By requesting feedback from each member of the …… .team, the management ensures that all problems are looked at and addressed ……..before they become significant.

Continuous improvement implemented for building a world-class Pakistan In this world no one is perfect there is always room for improvement but in our country there is a lot of thing that needs attention or improvement.

KAIZEN's approach to project management lends itself to a high degree of responsiveness. Operations allow us to expedite decision making, and to respond quickly to challenges and opportunities as they arise.

Kaizen implementations:

If Daewoo Pakistan or any other transport company is using Kaizen then they are more

favorite in the eye of traveler. We are here implementing Kaizen 5S model on Daewoo

Pakistan.

Kaizen steps which the Daewoo must use

Eliminate:

Daewoo must try to eliminate the problems which causing problems to their customers.

Reduce:

Reducing involves some of steps to reduce problem hindering to the quality service.

Change:

Daewoo comes with continues change in Pakistan road transport industry and to change the

journey standard of people.

5S of Kaizen:

Daewoo Pakistan is fulfilling their promises by providing quality services to customers. Daewoo

must be use 5s approach to maintain their quality.

Sei-ri (Organization)

Separating: Refers to the practice of going through all the tools, materials, in the work area and keeping only essential items. So the Daewoo must be separate their terminal according to the requirements or demand of the customers because there is a lot of crowd on the terminal. They must be separate terminal root wise divided in to parts.

Sei-ton (Neatness)

Sorting: Focuses on the need for an orderly workplace. Orderly in this sense means arranging the bus service tools and passengers luggage in an order that promotes traveling. It’s very important that each step has been done the correct place at the correct time. Daewoo must make sure that each and every employee must follow the company rules and regulations.

Sei-so (Cleaning)

Shine: To keep the BUSES or terminal clean as well as neat. Cleaning is a daily activity. At the end of each shift, the work area is cleaned up and everything is restored to its place.

Sei-ke-tsu (Standardization)

Standardizing: This refers to standardize your terminals and buses. It refers to more than standardized cleanliness this means operating in a consistent and standardized fashion. Everyone knows exactly what his or her responsibilities are. Daewoo must have some of play lands at terminals for children. As well as Daewoo must think how to provide entertainment to the children during journey. Some of customer’s complaints about that Daewoo some times not provide the fresh food. So Daewoo make sure to make happy the angered customers.

Shi-tsu-ke (Self-discipline)

Sustaining: Refers to maintaining standards. Once the previous 4S's have been established they become the new way to operate. Maintain the focus on this new way of operating, and do not allow a gradual decline back to the old ways of operating.These are "Sort, Straighten, Shine, Systemize and Sustain". "Standardize" is also used as an alternative for "Systemize". Sometimes "Safety" is included as 6th S it’s very important in our country like Pakistan to provide security to passengers.

4R’s of improvements which are very important in Daewoo:

1) Repair2) Refinement3) Renovation4) Reinvention

Apply kaizen on the Pakistan railway If we want to see our railway system in standardize form then we must implement kaizen in our railway. I am going to discuss some major areas that needs proper attention.

Setting up internal repair workshops

---Toilet vacuum unit overhaul---Catering overhaul---Bogie overhaul---Painting repair

Planning and review

There must be planning and reviewing departments. All the work done through proper planning, there is a two type of planning, fleet planning and depot planning which one can easily see or understand with the help of these pictures……

Fleet planning Depot Planning

KAIZEN in Just-In-Time system

Improvement is everyone's job. Think of ways to make ideas work. Don’t say .can’t. Don’t substitute money for brains. Ask Why? Five times. Improvement is not made from a conference room. More ideas are better, especially from people close to the problem. Follow up to make sure the idea is working. Improvement is endless.

Bogie overhaul program

1 train after every 9 days must be

--Tested--Bogie overhaul

Kaizen Promotion Office

There is need of kaizen promotion offices. The work of these offices is to check, which areas require improvement. Like….

Kaizen promotion offices set up Full time and part time staff

They are working on…..

Distances reduced Task times reduced Space for bogie overhaul Work arising task times reduced Health and Safety risks reduced

Setting up the Kaizen Promotion Office in pakistan railway

Traits that must be in Good Team Leaders

---Has experienced a kaizen event---Good knowledge of lean manufacturing (if production area event)---Good knowledge of waste elimination techniques---Not dictatorial - understands participative management---Comfortable working in the target area---Good people skills

Kaizen Event Sequence (Start to Finish)

1. Training & kick-off activities Tools of continuous improvement (pareto, fishbone, run charts, 5-whys, process analysis, etc.)2. Analysis of current “state”3. Select areas of focus4. Create possible solutions5. Select solutions6. Establish metrics for success7. Plan & implement (repeat if necessary)8. Standardize and sustain Paves the way for future events9. Report results10. Celebrate

Our government Offices needs Improvement

With the passing of time this dirt is gone our habits or good to say our need and we did not want to change the things or to see our environment clean and some time I think that we are feeling proud to see the polluted environment, may be behind that some of the reasons or truths that we did not want to listen like eat dirt, fling dirt, dirty soils, dirty work and last but not least is laziness and ignore our duties but these moral offences or sins are not the GOD gifted. These evils come in our soils due to our dirty thinking or may be discovery of mind.

Reason behind to discuss these problems, is to improve the things around us or to come with positive continues change in our daily life or professional life due to this one day we are proud of our-self. Start with small continues changes or improvements one day these small improvements convert into big change. For the purpose of this Japanese use kaizen,

kaizen is not just for Japanese we can also use according to our environment…like….

“Improvements in small steps”

A Japanese term for making improvements to a process through small, incremental amounts rather than through large innovations.

Before 5S After 5s

• The primary focus of 5S is the elimination of wastes in the work environment that result from unorganized, unclean material, tools, machines, desks, inventories, aisles, walkways, storage locations.

• To eliminate the wastes that result from” uncontrolled” processes.• To gain control on equipment, material & placement and position.• Apply Control Techniques to Eliminate Erosion of Improvements.• Standardize Improvements for Maintenance of Critical Process Parameters.

The way that must be use for packing orange, Apple or other fruits

The strategy behind that is…..

Orange Packing (1)

It is difficult to open net and put oranges in the net at the same time.

Productivity: 1 net per min.

Orange Packing (2)

Cooperation increases work efficiency.

Productivity: 5 nets per min.

A selection of better means or a change of current method for achieving an objective

Productivity: 10 nets per min.

When served a glass of water to someoneThese are some of the basic improvements that we needs

Placed the glass strongly on the tableHold the glass with care.Place the glass with care.Treat customers from your heart.Change the way of holding the glassHold the bottom of the glass.Support the glass with a little finger.

Suggestion SystemPropose improvement ideas for any activity in the company.Suggest your ideas, and examine them and implement some of these ideas later.

Suggestion System Concept

The suggestion system is an integral part of an established management system that aims at involving employees in Kaizen. The number of worker's suggestions is regarded as an important criteria in reviewing the performance of the worker's supervisor and the manager of the supervisor. management encourages employees to generate a great number of suggestions and works hard to consider and implement these suggestions, often incorporating them into the overall Kaizen strategy. Management also gives due recognition to employee's efforts for improvement. An important aspect of the suggestion system is that each suggestion, once implemented, leads to an upgraded standard.

Quality control (QC) circles can be viewed as a group-oriented suggestion system for making improvements. QC circle is a small group that voluntarily performs quality-control activities in the workplace. Total quality control (TQC) involves everyone in the organization and is aimed at improvement of managerial performance at all levels.

 

KAIZEN System

Propose only improvement ideas which will improve your own work.

KAIZEN sheet

Suggestion System

Workers. Responsibility Management responsibility

Workers. responsibility Management

responsibilit