KAIZEN

WHAT IS KAIZEN ?

THE KAIZEN IS A JAPANESE WORD WHICH MEANS :--

KAI MEAINS CHANGE & ZEN MEANS FOR THE BETTER
CHANGES FOR THE BETTER
BASICALLY A CONTINUAL IMPROVEMENT APPROACH
INVOLVES EVERYBODY IN THE ORGANIZATION
SMALL SMALL IMPROVEMENTS CARRIED OUT BY PERSONS WHO ARE DOING THE JOB IN THEIR WORK AREA.

WHAT IS OBJECTIVE OF KAIZEN ?
TO MAKE JOB EASIER & MORE EFFECTIVE
TO REDUCE ERRORS
TO REDUCE COST OF PRODUCTION/ SERVICE
TO INCREASE CUSTOMER SATISFACTION LEVELS

WHAT IS KEY TO SUCCESS FOR KAIZEN ?

FAITH IN EMPLOYEE & KAIZEN
TRUST
TOTAL COMMITMENT FROM TOP TO DOWN
EMPOWERMENT
CONVICTION

WHAT IS BASIC PRINCIPLE ?

Ø EMPLOYEE WORKING IN A PARTICULAR AREA IS MORE AWARE ABOUT THE PROBLEMS PERTAINING TO HIS WORK AREA.
Ø EMPLOYEE SOMETIMES IS AWARE ABOUT THE SOLUTIONS TO THE PARTICULAR PROBLEM
Ø IF THE EMPLOYEE IS GIVEN FREEDOM & IS TRUSTED, THE EMPLOYEE MAY WORK WONDERS OR DO MIRACLES AT HIS WORKPLACE.
Ø ADOPTING THE APPROACH OF “ WE TRUST YOU THAT YOY KNOW THE JOB BEST “ BY THE EMPLOYER MAY GIVE BEST RESULTS.
Ø JAPAN HAS ACHIEVED MIRACULOUS CHANGES THROUGH SMALL IMPROVEMENTS ONLY.
Ø UTILIZATION OF COLECLTIVE WISDOM OF EMPLOYEES PRODUCES BEST RESULTS.

WHY KAIZEN ?

Ø IN THE GLOBAL COMPETITIVE ENVIRONMENT, AN ORGANIZATION IS REQUIRED TO CHANGE FOR THE BETTER WHICH MEANS KAIZEN.
Ø TO BECOME WORLD CLASS ORGANIZATION.
Ø TO MAKE OUR CUSTOMER HAPPIER BY IMPROVING THE SERVICE PROVIDED TO THE CUSTOMER.
Ø TO WORK SMARTER & NOT HARDER.
Ø TO MAKE WORK EASIER & SAFER.
Ø TO IMPROVE QUALITY & REDUCE COST.
Ø TO LEAD ORGANIZATION TOWARDS GROWTH.
Ø TO ENABLE / EMPOWER THE EMPLOYEE TO IMPLEMENT HIS IDEAS & GET SATISFACTION
Ø TO ENABLE EMPLOYEE TO GET MOTIVATED.

WHEN TO DO KAIZEN ?

Ø WHENEVER THERE IS :

PROBLEM FACED BY AN INDIVIDUAL
PROBLEM FACED BY THE ORGANIZATION
DISSATISFACTION FACED OVER WORKING METHOD

WHO SHOULD DO KAIZEN ?

Ø BY EVERYONE FROM TOP TO BOTTOM IN THE ORGANIZATION.
Ø EVERY EMPLOYEE IS CONTRIBUTING TO ORGANIZATION’S OUTPUT THROUGH HIS SINCERE & DEDICATED INVOLVEMENT .


WHERE KAIZEN (AREAS) ?

v KAIZEN CAN BE DONE IN AREAS :--

IN ONE’S OWN AREA OF WORK

§ ROUTINE AREAS

Ø USE OF DEVICES/ FORMATS TO SAVE TIME & REDUCE FATIGUE
Ø IMPROVING FILING SYSTEM IN ORDER TO MINIMIZE SEARCH TIME
Ø USING PLATFORM OF SAME HEIGHT FOR UNLOADING MATERIAL FROM THE TRUCK.
Ø CONTROL OF DOCUMENTS FOR QUICK RETRIEVAL OF DOCUMENTS
Ø COMBINING TWO FORMS INTO ONE FOR SAVING TIME

IN OTHER’S WORK AREAS

ü CANTEEN
ü RECEPTION
ü OFFICE
ü STAIR CASES
ü UTILITY

IN THE COMMON WORK AREA

ü WITH YOUR DEPARTMENT’S COLLEAGUES
ü WITH OTHER DEPARTMENTS IN THE ORGANIZATION

HOW TO IMPROVE ?

IMPROVEMENTS DO NOT COME ABOUT BY COINCIDENCE.
IMPROVEMENTS ARE RESULTS OF CONCIOUS EFFORTS TOWARD THEM.
THERE IS ALWAYS A SYSTEMATIC WAY OF MAKING IMPROVEMENTS.
EVERYONE IN THE ORGANIZATION CAN CONTRIBUTE TOWARDS KAIZEN PROGRAMME.

SEVEN POINTS TO BE REMEMBERED FOR IMPROVEMENTS ?
1. START WITH IMOVEMENTS

DON’T IGNORE SMALL PROBLEMS/ SMALL WASTE AS TRIEVAL MATTER
DON’T ACCEPT A CERTAIN AMOUNT OF WASTE AS INEVITABLE.

v 2. START WITH YOUR PROBLEM & NOT THEIR PROBLEMS

v IMPROVEMENTS ALWAYS START AT HOME
v USE YOUR OWN CREATIVITY
v LARGE POTENTIAL FOR IMPROVEMENTS IS AVAILABLE IN YOUR OWN AREA.

v 3. START WITH EASY AREAS

§ APPLY 5S AT YOUR WORK PLACE.
§ APPLY 3 ‘ MU ‘ PRINCIPLES i.e MUDA, MURA, MURI

§ IMPROVE YOUR MOVEMENTS WHILE PERFORMING THE JOB.
§ LOOK AT ALL UNNECESSARY MOVEMENTS ( YOURS ) & ELIMINATE THEM
§ STORE THE NECESSARY TOOLS/ INSTRUMENTS NEAR THE PLACE OF WORK

v 4. CONSIDER THE IMPROVEMENTS AS DAILY PART OF ROUTINE

v DON’T TREAT IMPROVEMENTS AS EXTRA WORK, TREAT THEM AS PART OF DAILY ROUTINE.
v MAKE CONTINUAL IMPROVEMENT THROUGH INVOLVEMENT OF ALL
§ STORE THE NECESSARY TOOLS/ INSTRUMENTS NEAR THE PLACE OF WORK

v 5. COLLECT GROUP WISDOM

v IDENTIFICATION OF PROBLEMS & FINDING OUT PROBLEMS BECOMES EASIER WHEN DONE JOINTLY .
v WIRE ROPE IS MORE STRONG THEN INDIVIDUAL STRAND IN IT. THROUGH INVOLVEMENT OF ALL

v 6. NEVER REJECT ANY IDEA BEFORE TRYING
7. HIGHLIGHT THE PROBLEMS, DO NOT HIDE THEM

WHAT ARE SEVEN STEPS FOR IMPROVEMENTS ?

v 1. PROBLEM IDENTIFICATION
v 2. ANAYSIS/ RESEARCH
v 3. IMPROVEMENT GOAL SETTING
v 4. IDEA FORMATION
v 5. IDEA SELECTION/ MODIFICATION
v 6. IMPLEMENTING THE IMOVEMENT PLAN
v 7. FOLLOW UP ON IMPLEMENTATION


WHAT ARE FOUR PHASES OF KAIZEN ?

v 1. MOTIVATION PHASE ( MANAGEMENT PHASE)

§ TOTAL EMPLOYEE INVOLVEMENT
§ ELIMINATE ALL TYPES OF WASTE
§ CHANGE THE ATTITUDE OF EMPLOYEES
§ SELF MANAGED EMPLOYEES

v 2. HRD PHASE

§ NEED BASED PEOPLE BUILDING PROGRAMMES TO BE ARRANGED
§ INCULCATE A FEELING OF “ TASK IS MINE “ & “ ORGANIZATION IS MINE“
§ USE OF 7 QC TOOLS
§ MAKE EMPLOYEES MORE QUALITY LITERATE SO THAT THEY CAN CONTRIBUTE TOWARDS IMPROVEMENTS.

v 3. IMPROVEMENT PHASE
§ APPLICATION OF QUALITY CIRCLES

v 4. INSTITUTINALISE KAIZEN PHASE
§ QUALITY CONTROL AUDIT
§ BENCHMARKING

§ WHAT ARE FIVE PHASES OF FRUIT BEARING ?
§ NESTING PHASE
§ TESTING PHASE
§ INVESTING PHASE
§ ARRESTING PHASE
§ CREATIVE PHASE

NOW BELIEVE & YOU WILL ACHIEVE.