+ S |KAIZENdebrina.lecture.ub.ac.id/files/2016/02/TQM-Kaizen... · 2016. 2. 11. · 5 ‘S’ IN KAIZEN ¡ 5S is a method for organizing a workplace, especially a shared workplace

O le h :

Debr ina P. Andr iani Te k n ik Indus t r i Un i ve r s i t as B raw i jaya þ de br ina@ ub .ac . id

+ S | K A I Z E N C O N T I N U O U S I M P R O V E M E N T I S T H E R E S U L T O F C O N T I N U O U S I N V O L V E M E N T

T O T A L Q U A L I T Y M A N A G E M E N T

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¡  Kaizen- An Introduction ¡ What Is Kaizen ¡  Features Of Kaizen ¡  Phases In Kaizen ¡  Benefits Of Kaizen ¡  Contents Of An Operation ¡ What Is Obvious Waste? ¡ Workplace Organization ¡ Workflow – Line Balancing ¡  Traditional Method Vs Kaizen ¡  10 Ground Rules For Kaizen ¡  5 ‘S’ In KAIZEN ¡  Pit Falls In Kaizen

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Masaaki Imai is known as the

developer of Kaizen.

KAIZEN- AN INTRODUCTION

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WHAT IS KAIZEN

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KAIZEN

LowCost ContinuousImprovement

Kaizen denotes continuous improvement. Kaizen aims to eliminate all wastes in business processes through standardization in the processes and activities of a business entity. Change making and result monitoring make Kaizen highly effective.

WHAT IS KAIZEN?

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WHAT IS KAIZEN?

Assess/Reassess

Plan and Design

Implement

Evaluate

K a i z e n a c t i v i t i e s t h a t a d d r e s s i s s u e s o v e r a period of one week had become the industry norm and they had been named a s ‘K a i z e n e v e n t s’ . These small models are u s e d t o u n d e r s t a n d problems and issues in the business processes, arrive at so lut ions , and apply t h e m t o i m p r o v e t h e processes and el iminate wastes.

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¡ So basically kaizen is small incremental changes made for improving productivity and minimizing waste.

¡ 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.

WHAT IS KAIZEN?

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FEATURES OF KAIZEN •  Can be used in both manufacturing and non-

manufacturing environments Widely applicable

•  Kaizen events will generate quick results, Measurable results, Establish the baseline, and measure the change!!!

Highly effective & results oriented.

•  Every member of a Kaizen Team will walk away from the event learning something new! !

A Learning Experience

•  Team members can be from various functions of the business. Top management participation is encouraged.

Team based & cross functional

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PH

ASES IN

K

AIZEN

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A.) Select an Event B.) Plan an Event

C.) Implement an Event D.) Follow-up to an Event

THESE STEPS ARE SHORTEN INTO :

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¡  Kaizen Reduces Waste- like inventory waste, time waste, workers motion

¡  Kaizen Improves product quality

¡  Results in higher employee moral and job satisfaction,.

¡  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.

BENEFITS OF KAIZEN

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CONTENTS OF AN OPERATION

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WHAT IS OBVIOUS WASTE?

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WORKPLACE ORGANIZATION

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WORKFLOW – LINE BALANCING

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SMED QUICK TOOL CHANGEOVER

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TRADITIONAL METHOD VS KAIZEN

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10 GROUND RULES FOR KAIZEN

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5 ‘S’ IN KAIZEN ¡  5S is a method for organizing a workplace,

especial ly a shared workplace (l ike a shop f loor or an off ice space), and keeping i t organized.

¡  To take the concept of Kaizen performance to i ts ult imate level of simplicity, i t offered the fol lowing "5S" steps

§  Sorting keeping only essential items §  Simplifying eliminates extra motion. §  Sweeping keep the workplace clean

§  Standardizing standardized work practices §  Sustaining maintaining and reviewing standards

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¡ Resistance to change

¡ Lack of proper procedure to implement

¡ Too much suggestion may lead to confusion and time wastage

PIT FALLS IN KAIZEN

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SELESAI