The Prime Mover

“The Prime Mover – Towards Excellence” 0Bajaj Auto Limited


Contents

Sr. Description Slide No.

1 Kaizen meaning with Example 2 - 4

2 Overview & Implementation 5 - 6

3 Difference between basic condition restoration & Kaizen 7 - 9

4 Kaizen Principles 10 - 12

5 Kaizen process 13

6 Kaizen Eye for Key parameters 14

7 Kaizen Examples 15 - 17

8 Key fields explanation 18 - 30

9 Characteristics of a good kaizen 31


KAI ZEN

Change Good

Japanese Language

Pronunciation

English Language

English Meaning The literary meaning of Kaizen is “change for good”.

Kaizen Meaning

❖ Kaizen is a Japanese word which simply means "change for good / better“.


Before After

Kaizen Example

Difficult, More Fatigue Easy, Less or no fatigue


Before After

Kaizen Example

More searching time No searching time

More searching time No searching time


❖ The Japanese word Kaizen simply means "change for good / better“.

❖ The word refers to any improvement, one-time or continuous, large or small, in the same sense as the English word "improvement".

❖ However, given the common practice in Japan of labeling industrial or business improvement techniques with the word "kaizen", particularly

the practices spearheaded by Toyota, the word "kaizen" in English is typically applied to measures for

implementing continuous improvement.

❖ Two kaizen approaches have been distinguished:

▪ Flow kaizen - oriented towards the flow of materials and information, and is often identified with the reorganization of an

entire production area or service area, even a company or a workshop.

▪ Process kaizen - the improvement of individual work stations or bays. Therefore, improving the way production workers / workshop

employees do their job is a part of a process kaizen.

❖ The use of the kaizen model for continuous improvement demands that both flow and process kaizens are used.

❖ Process kaizens are used more often to focus workers or workshops employees on continuous small improvements. In this model, operators

or workshops employees mostly look for small ideas which, if possible, can be implemented on the same day.

❖ Kaizen is a daily process, the purpose of which goes beyond simple productivity improvement, Service volume improvement, TAT reduction,

Service Quality improvement, Repeat jobs reduction, Customer complaints reduction or Non moving inventory reduction etc.

❖ It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work, and teaches people how to perform

experiments on their work using the scientific method and how to learn to spot and eliminate waste in business processes.

Overview


The Toyota Production System is known for kaizen, where all line personnel are expected to stop their moving production line in case of any abnormality and, along with their supervisor, suggest an improvement to resolve the abnormality which may initiate a kaizen.

The PDCA cycle-The cycle of kaizen activity can be defined as: "Plan → Do → Check → Act". For kaizen, PDCA can also be defined as “Problem finding → Display → Clear → Acknowledge".

Implementation

PDCA cycle

PDCA cycle for Kaizen


• Many times people gets confused in Basic condition restoration & Kaizen.

• Basic condition is what a thing normally should be.

• Basic condition restoration can not be considered as Kaizen.

• These two are different things.

• Kaizen is an improvement action taken after restoration in 4M condition.

Abnormal ConditionNormal Condition

(Basic condition restoration)Kaizen

Water leakage from tap No water leakage from tap Rubber washer replaced with silicone washer for more life

Example :-

Difference between basic condition restoration & Kaizen


Category ExampleBasic requirements as per BAL

normsWhat is basic condition restoration

(Few examples are given below)What is Kaizen ?

(Few examples are given below)

Man Direct manpowe

r (MSO)

In vehicle assembly, X manpower is required for line setting of 500/shift.

Provided X manpower for the line setting.

1. Action for operators productivity improvement is Kaizen.2. Action taken for deskilling of operation is Kaizen.3. Action taken for fatigue reduction is Kaizen.

In vehicle assembly, X manpower is required for PV for line setting of 500/shift.

Provided X manpower for PV. 1. Action for operators productivity improvement is Kaizen.2. Action taken for deskilling of operation is Kaizen.3. Action taken for fatigue reduction is Kaizen.

Machine Tools, equip-ments

1. Availability of all special tools. 1. Provision of special tool kit. 1. Action to increase life of special tools is Kaizen.

2. Action to maintain quality of special tools is Kaizen.

3. Action to reduce searching time loss of special tools is

Kaizen.

4. Action to reduce waiting time of operators for measuring

instruments is Kaizen.

2. Availability of all diagnosis tools.

2. Purchased all diagnosis tools.

3. Availability of all measuring instruments.

3. Purchased all measuring instruments.

Given below the examples of basic condition restoration & Kaizen in 4M conditions.



Category ExampleBasic requirements as per BAL

normsWhat is basic condition restoration

(Few examples are given below)What is Kaizen ?

(Few examples are given below)

Method Processes, SOPs

1. Adherence to PDI 1. PDI team trained & PDI activity streamlined.

1. Action to reduce PDI time is Kaizen. (Without sacrificing Quality)

2. Action to adhere PDI for 100% vehicles is Kaizen.3. Action to prevent any issue travelling beyond its step is

Kaizen.4. Action to improve space productivity at PDI is Kaizen.

2. Adherence to Final inspection 2. Final inspection activity with modified check sheet streamlined.

1. Action to reduce Final inspection time is Kaizen. (Without sacrificing Quality)

2. Action to adhere Final inspection for 100% vehicles isKaizen.

3. Action to prevent any issue travelling beyond its step is Kaizen.

4. Action to improve space productivity at Final inspection is Kaizen.

Material(Money)

Facilities(Infra-

structure)

1. Availability of drinking water, toilet, canteen for workmen

1. Provision of facilities like air conditioning, better & comfortable working conditions

1. Action to increase comfort of workmen while working is

kaizen

2. Action to reduce Drinking water procuring cost is Kaizen.

3. Action to reduce cost loss of water due to wastage (not

leakage) is Kaizen.

4. Action to reduce the cleaning agents procuring cost is

kaizen.


Given below the examples of basic condition restoration & Kaizen in 4M conditions.


Kaizen Principles

Given below are the Ten Kaizen principles.


Kaizen Principles


Kaizen Principles


▪ The Kaizen story (or Kaizen process) is built on PDCA mnemonic –Plan, Do, Check and Act.

▪ The Kaizen process is a seven step basic procedure which allows any individual or team to solve problems scientifically, rationally,

effectively and efficiently.

Defining the problem.

Understanding /assessing the current status.

Finding the root cause.

Planning counter

measures.

Implementing counter

measures.

Verifying results.

Standardizing and

establishing control

Seven steps of Kaizen process

Kaizen process

Plan DO Check Act


Parameters Description

THEME To Reduce / To Eliminate / To Increase / To Prevent

PROBLEM / CURRENT STATUS

Correct observation

5W 1 H ( What, When, Where, Which, Who, How)

Analysis Analysis is done to find out the root cause of the problem / current status with the help of Why Why Analysis

Root cause with KEY words.(Answer of last Why is the root cause)

1. Poka (Mistake)

2. Less friction

3. Fully

4. Many Bolts

5. More (Inventory)

6. Big

7. Long

8. Non detectable

9. Difficult

IDEA (Opposite to root cause)

1. Pokayoke (Mistake proof)

2. More friction

3. Partly

4. Less Bolts

5. Less (Inventory)

6. Small

7. Short

8. Detectable

9. Easy

COUNTERMEASURE Provided / changed

RESULT Reduced searching time / reduced motion loss / reduced frequency / increased life /

prevented defect of /prevented accidents at …..

BENEFIT Increased production / increased service volume / reduced repeat jobs / reduced customer

Complaints / Reduced cost

Kaizen Eye for Key parameters

• Given below are the Key parameters in Kaizen.

Kaizen examples are given on next slides from which it will be easy to understand the Kaizen filling as per the Kaizen Eye.

Inte

rlin

ked

par

amet

ers

(eg

-R

esu

lt &

ben

efit

are

rel

ated

to

Th

eme

)

Bajaj Auto Limited

Kaizen Examples

❖ Few Kaizen examples are given in following slides.

❖ The “Kaizen Eye” is used for kaizen sheet generation.


Kaizen Example - 1


Kaizen Example - 2

Bajaj Auto Limited

Key fields - explanation

❖ There are some Key fields in the kaizen which are explained ahead-

A. Kaizen Theme

B. Problem / Current Status

C. Analysis

D. Root cause & Idea

E. Countermeasure

F. Result

G. Benefit


A. Kaizen Theme

❖ Always start the Kaizen Theme with words like - To increase / To reduce / To eliminate / To prevent

❖ Kaizen theme is to be derived from Problem / Current Status

Examples -

▪ To increase output per man / To increase output per hour.

▪ To reduce motion loss / To reduce inventory carrying cost.

▪ To eliminate defect of zero clutch play / To eliminate the unsafe condition at unloading counter.

▪ To prevent the possibility of cut injury while chain greasing / To prevent the possibility of defect of fork loose fitment.

❖ Selection of words for Kaizen theme –

▪ To increase – Start Kaizen themes with this word for showing improvement in Positive parameters.

▪ To reduce - Start Kaizen themes with this word for showing improvement in Negative parameters.

▪ To eliminate - Start Kaizen themes with this word for happened cases like accident / defect / breakdown (Reactive approach

– happened in past but should not happen in future).

▪ To prevent – Start Kaizen themes with this word for possible accident / defect / breakdown cases which may happen in

future (Proactive approach).


Kaizen Theme - Example

A KMI (Key Management Indicator) or KPI (Key Performance Indicator) itself can not be taken as a Kaizen Theme.

Examples -

• Production can not be increased with any single Kaizen or productivity can not be increased with a single kaizen.• The big task / aim / target is to be divided in to small pieces of activities and for each activity there can be “N” numbers of Kaizen.• Achievement of Result depends on persistent actions & supported by good kaizen.

Activity 1(OLE Improvement)

Activity 2(Capacity Enhancement)

Activity 3(Flexibility)

Activity 4(Increase Output/man)

Activity 5(…….)

Activity 6(…….)

1. 16 major losses

elimination

2. Tool change loss

elimination

by providing low cost

automation

3. …….

4. …….

5. …….

1. Apply the principles of

motion economy

2. Reduce non-value added

activities

3. Arranging the parts to

ensure easy pick up

4. …….

5. …….

6. …….

1. ….

2. ….

3. ….

4. ….

5. ….

6. ….

1. ….

2. ….

3. ….

4. ….

5. ….

6. ….

Big task / aim / target(Eg- Increase Production)

1. De-bottlenecking

2. Increase production per

hour

3. De-bottlenecking

through the ECRS

activities.

4. ….

5. ….

6. ….

1.Increase No. of flexible

cells

2.Increase No. of models

in same facility

3. …….

4. …….

5. ……..

Given below an example -


▪ Problem means the thing which we do not want to happen.

▪ These are the parameters for which the Target is always Zero.

Sr. Parameter UOMCurrent status

(Aug’21)Target

1 Early failures % 1.2

Zero

2 Customer complaints % 0.4

3 Warranty claims % 6.5

4 IRU Complaints % 9.3

5 VOR Nos. 14

6 Non-moving inventory Rs. (Lac) 4.2

7 PDI Complaints % 3.1

8 Machine / Equipment breakdown Min. 80

9Accidents

(First aid injuries, Minor accident & Major accident)Nos. 3

Example -

B. Problem / present Status



▪ Present status means the thing which we can not avoid but we want to change it's present status or we want to improve it further.

Sr. Parameter UOMCurrent status

(Aug’21)Target

1 Rework time (eg. - Clutch replacement) Min. / Veh 2 1

2 Set up change Min. / stage 20 15

3 Fuel cost Rs. / Veh 10.5 9.0

4 Power cost Rs. / Veh 17 15

5 Water cost Rs. / Veh 12 10

6 Stationary cost Rs. / Veh 2.5 1.8

7 Telephone charges Rs. / Veh 3.5 3.0

Example -



Writing the Problem / Current Status means mentioning the correct observation of the phenomenon in the form of

5W 1H where 5W 1H means –

• What - Object

• When - Activity

• Where - Location

• Which – Stage / exact location / model

• Who – Human (Person / Operator / Individual)

• How (much) – Quantification of problem / present status

At PV area (Where), @ 2.1 % (How much) carburetor replacement (What) done for low CO (When) particularly in 100-125 cc segment (Which).

Engine tuning is found NOK for less mileage. Engine tuning is done by manual judgment.

Problem / Current Status - Example


C. Analysis

▪ Carry out Why Why analysis for finding out root cause of the problem.

▪ First Why of the Why Why analysis will be the parameter which is to be improved.

▪ Find out the answer of first why.

▪ The answer of first Why will be the second Why & the answer of second why will be the third why.

▪ Continue the question answer till you find the root cause.

▪ In most of the cases, root cause can be find in five steps.

▪ If Why Why is still carried out further, you will find a illogical answer.

Example -▪ Why 1 – Problem or the parameter which is to be improved▪ Ans 1 - Answer of Why 1

▪ Why 2 - Convert answer of Why 1 in question▪ Ans 2 - Answer of Why 2



▪ Why 5 - Convert answer of Why 4 in question▪ Ans 5 - Answer of Why 5 – This may be the root cause of the problem


Analysis - Example

A robot has stopped working during the operation

Problem -

Root cause of the problem

▪ Why 1 – Why did the robot stop?▪ Ans 1 - The circuit has overloaded, causing a fuse to blow.

▪ Why 2 - Why is the circuit overloaded?▪ Ans 2 - There was insufficient lubrication on the bearings, so they locked up

▪ Why 3 - Why was there insufficient lubrication on the bearings?▪ Ans 3 - The oil pump on the robot is not circulating sufficient oil.

▪ Why 4 - Why is the pump not circulating sufficient oil?▪ Ans 4 - The pump intake is clogged with metal shavings.

▪ Why 5 - Why is the intake clogged with metal shavings?▪ Ans 5 - Because there is no filter on the pump. (Root cause)


D. Root cause & Idea

▪ Answer of last Why will be the root cause.

▪ The opposite of root cause will be the Idea.

Examples -

Root cause Idea

The defect is Non detectable X To make the defect Detectable

The distance is More X To make the distance Less

There is No lubrication at joints X To provided Lubrication at joints

There is No PDI X To start the 100% PDI

There is No Check sheet in place X To provide a Check sheet

It is Difficult to access the area. X To make the area Easy to access.

The activity is Manual X To make the activity Automatic

The special tool cost is High X To make special tool available at low cost


E. Countermeasure

➢ Countermeasure is the corrective action taken on the “problem or present status”.

➢ Always start countermeasure with provided / changed etc & then give details like -

▪ Developed a special tool for head light focus adjustment.

▪ Provided a new format for recording in process defects / errors.

▪ Provided facility to note reduction of non-moving material.

▪ Changed the current method for liquidation of non-moving material.

▪ Changed the contents of training material for ease of understanding & explanation for new employees.

Countermeasure - Example

Developed a small low cost digital tachometer which can be used for checking Idling RPM at PV area.


F. Result

➢ Result should be in relation to the kaizen theme. Start result like reduced by, increased by, eliminated, prevented and show it by Graph

with unit of measurement (before and after).

▪ Reduced customer complaints by 4.2 % (Graph of the same is given below).

▪ Reduced non-moving inventory by Rs.......

▪ Increased adherence to delivery by .... min / veh

▪ Reduced down time by ....min / veh

Graph example

4.2

00

1

2

3

4

5

Before After

%

Customer Complaints


Result - Example

➢ Total rework jobs reduced from 5% to 2.9%.

2.1

00

0.5

1

1.5

2

2.5

Before After

%

Rework for less mileage

5

2.9

0

1

2

3

4

5

6

Before After

%

Total Rework

➢ Eliminated rework of less mileage due to engine tuning errors.


G. Benefit

➢ Benefits are the outcomes / gains of the kaizen on a larger perspective whereas Result is the direct impact of the kaizen on a particular

parameter for which the Kaizen is implemented.

➢ Benefit of a Kaizen will always be either Profit Up or Cost Down

➢ Benefit will always be a KMI / KPI.

Benefit - Example

1. Reduced total rework.

2. Reduced tool cost of Tachometer.

3. Increased output per man.


➢ A good Kaizen : is simple offers the simplest and best way to achieve the purpose, effective (fixes the problems permanently) and revolutionary

(looks from view not explored earlier).

➢ A good Kaizen : provides permanent solution to the problems by identifying their root causes.

➢ A good Kaizen : corresponds to departmental and company’s goals and policies.

➢ A good Kaizen : makes effective use of available resources.

➢ A good Kaizen : requires little or no investment to implement.

➢ A good Kaizen : produces no negative side effects (I.e. does not give rise to new problem in the same or other areas).

Characteristics of a good kaizen


All the best for Kaizen Journey…!!

“Make hidden problem

visible,

Do immediate kaizen.”

Prof. Nomura

“Kaizen has no limit

(endless). Any action done is

always a seed for the next

kaizen.”

Taichi Ohno

“If the Kaizen is not

enjoyable, it is not a real

Kaizen”

Taichi Ohno

Documents

The Prime Mover