This Gemba kaizen sample 30 slides is only part from the original 128 slides. Kaizen Definition KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination What is MUDA? Muda means any wasteful activity or any obstruction to smooth flow of an activity Activity = Work + Muda Expenditure = Cost + waste That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!

1. GEMBA KAIZEN By Ismail Clement http://gembakaizenemailconsultancy.weebly.com/ 1 Gemba Kaizen Email Consultancy

2. 2 GEMBA KAIZEN INTRODUCTION GEMBA KAIZEN HOW TO MANAGE QCD IN GEMBA STANDARDS 5 S MUDA THE FOUNDATION OF THE HOUSE OF GEMBA VISUAL MANAGEMENT SUPERVISORS ROLE IN GEMBA Gemba Kaizen Email Consultancy

3. 3 CHAPTER ONEINTRODUCTIONTOGEMBA KAIZEN Gemba Kaizen Email Consultancy

4. 4 What is Kaizen? Kaizen means ‘change for the better’ in Japanese. The best English equivalent is ‘improvement'. Kaizen is made up of two characters: Gemba Kaizen Email Consultancy

6. Many of the concepts and tools of kaizen came from industrial engineering and Dr. Edward Deming's teachings. Masaaki Imai's book 'Kaizen' made it a common word outside Japan back in the 1980s. 5 Gemba Kaizen Email Consultancy

8. What is an internal customer?

9. What is the value to the customer?Gemba Kaizen Email Consultancy

11. What causes the waste?

13. How to waste less resources?

14. How can we do both?Gemba Kaizen Email Consultancy

18. 11 KAIZEN Is continuous improvement. The KAIZEN philosophy - is our way of life and should focus on constant improvement efforts. The improvements are small and incremental. KAIZEN process are based on commonsense and low cost approaches. RUSSIAN Gemba Kaizen Email Consultancy

19. 12 MAJOR KAIZEN CONCEPTS KAIZEN and management. Process versus result. Following the PDCA/SDCA. Putting quality first. Speak with data. The next process is the customer. Gemba Kaizen Email Consultancy

20. 13 KAIZEN AND MANAGEMENT Has two major functions: Maintenanceand Improvement. Maintenance: current technological, managerial and operating standards. Improvements: activities directed toward elevating current standards. Gemba Kaizen Email Consultancy

21. 14 Japanese Perceptions Of Job Functions Top management Middle managementImprovement Supervisors Maintenance Workers Gemba Kaizen Email Consultancy

22. 15 KAIZEN n TECHNOLOGY Whenever money is a key factor, innovation is expensive. Kaizen emphasizes human efforts, morale, communication, training, teamwork, involvement and self discipline – a commonsense low cost approach to improvement. Gemba Kaizen Email Consultancy

23. 16 Improvement Broken Down Into Innovation Top managementInnovation Middle managementKaizen Supervisors Maintenance Workers Gemba Kaizen Email Consultancy

25. SDCA

26. QCD

27. TQM

28. TPMKaizen strategies have failed many companies simply because they ignored process. The most crucial element in the kaizen process is the commitment and involvement of top management. Gemba Kaizen Email Consultancy

29. 18 Following the PDCA/SDCA Cycles The first step in the kaizen process establishes the PDCA cycle. Plan refers to establishing a target for improvement. Do refers to implementing the plan. Check refers to determining whether the implementation remains on track. Gemba Kaizen Email Consultancy

30. 19 Cont. Act refers to performing and standardizing prevent recurrence of the original problem or to set goals for the new improvement. The PDCA cycle revolves continuously. Management must initiate PDCA by establishing continuously challenging goals. Before working on PDCA, any current process must be stabilized. Gemba Kaizen Email Consultancy

32. Did it happen because the standard was not followed?

33. Did it happen because the standard was not adequate?Gemba Kaizen Email Consultancy

34. 21 Cont. SDCA standardizes and stabilizes the current process. PDCA improves the current process. SDCA refers to maintenance and PDCA refers to improvement, these become the two major responsibilities of management. Gemba Kaizen Email Consultancy

35. 22 IMPROVEMENT - PDCA ACT PLAN P A D C DO CHECK Gemba Kaizen Email Consultancy

36. 23 MAINTENANCE - SDCA STANDARDIZE ACT s A C D DO CHECK Gemba Kaizen Email Consultancy

37. 24 PUTTING QUALITY FIRST Of quality, cost and delivery, which should always have the highest priority? ? concept requires management commitment. Managers often face the temptation to make compromises in meeting delivery requirements or cutting cost. Gemba Kaizen Email Consultancy

38. 25 SPEAK WITH DATA KAIZEN is a problem solving process. The problem must be understood and recognized. Solving a problem without data is not a very scientific or objective approach. Collecting, verifying and analyzing data for improvement is vital. Gemba Kaizen Email Consultancy

39. 26 THE NEXT PROCESS IS THE CUSTOMER The next process should always be regarded as the customer. Refers to two types of customers: internal and external. When everyone in the organization practices this the external customer will receive a high quality product or service as a result. Gemba Kaizen Email Consultancy

41. A just in time production system.

42. Total productive maintenance.

43. Policy deployment.

44. A suggestion system.

45. Small group activities.Gemba Kaizen Email Consultancy

46. 28 TQC / TQM One of the principles of Japanese management has been TQC in its early development. This has evolved into a system encompassing all aspects of management and is now referred to as TQM – a term used internationally. TQC / TQM should not be regarded as strictly as a quality control activity: It has developed as a strategy to aid management to be more competitive and profitable by helping it to improve in all aspect of business. Gemba Kaizen Email Consultancy

47. 29 Cont. “Q” meaning quality, has priority but there other goals too – namely cost and delivery. “T” signifies total, meaning that it involves everybody in the organization. “C” refers to control or process control. In TQC/TQM key process must be identified, controlled and improved on continuously in order to improve results. Gemba Kaizen Email Consultancy

48. 30 TQM Quality assurance Quality control inspection Aim for continuous improvement / Involve suppliers & customers / Involve all operations / Performance measurement / Team work / Employee involvement Third party approval, systems audits, advanced quality planning, involvement of non production operations, failure mode and effect analysis, statistical process control Develop quality manual, process performance data, self inspection, product testing, basic quality planning, use of basic statistics, paper work control Salvage, sorting, grading, corrective actions, identify sources of non conformance Gemba Kaizen Email Consultancy