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Prepared by:Prepared by: Obaid BilgaramiObaid BilgaramiManager CoordinationManager Coordination
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The most Pragmatic, Down-To-Earth andProcess Oriented Manufacturing Approaches.
More focused on Process Improvement(New Manufacturing Vision).
Effective Efficiency Optimizing Approach
(Not Efficiency Maximizing Approach).Stepping stone top other manufacturing
standards, i-e; Lean, ISO 9000, TS 16949,etc.
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Kaizen
5S.
GembaGenchi Genbutsu
Obeya
Poka YokeJidoka
Andon
Kanban/Pull System
Muda, Mura, Muri
HeijunkaFIFO
Takt Time
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A combination of two Japanese words:Kai = Change & Zen = Better
i-e;Change for Better
Kaizen Cycle (Good Better Best)
Kaizen Mind
Kaizen Procedure
Before/ After Approach
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Seiri (Sorting)
Seiton (Setting)
Seiso (Sweeping)
Seiketsu (Standardizing)
Shitsuke (Sustaining)
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The word literally means The Place wheretruth can be found and refers to The Place
Where the Activity is happening like CrimeScene, Play Ground, Production Floor, etc..
The availability of Incharges, i-e;
Production, QC, Maintenance at floor toensure system effectiveness and FactualAnalysis of Problem if occurs.
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The word literally means Go See foryourself referring to the Gemba Attitude, i-
e; instead of depending on hearsay,reports, summary charts, or any docs, getout and visit the place where actually the
problem occurs.This attitude enables an effective and
most appropriate decisions based on On
the Spot Analysis.
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The word literally means Big Room andrefers to The room where reports/ results/
Summaries & Performances are displayedfor Management Perusal.
The Management holds meeting to
evaluate the Deptt. Performance/Issues,Activities Status and propose rationaldecisions.
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The word literally means Mistake Proof and refers to Any device, limits or system
installed at operations to ensure zerodefect/ error/ mistake.
The Zero Defect Target can only be
achieved if the abnormality is stopped at itsplace of origin, this is what poka yoke for.
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The word literally means Automation orIntelligent System and refers to Machine
to be built/added with devices or limitsensors to stop in case of an abnormality.
This system is to ensure fast, effective
and reliable means of production toeliminate inadvertent errors, negligence,maintenance failure like Poka Yoke.
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The word literally means Paper Lantern and refers to status-display station or a
system to notify management,maintenance, and other workers of a qualityor process problem.
This is another example of Jidoka toeliminate the error/ defect at its place of origin with Problem Identification at
machines
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The word literally means Visual Card andrefers to Kanban is a signaling system to
trigger action. In kanban, cards are used tosignal the need for an item from InventoryStock or suppliers .
It is based on Pull System and also refersto JIT System which is another hallmark of Japanese Manufacturing System.
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The word literally means Level andrefers to a system of production
smoothing/ leveling designed to achieve amore even and consistent flow of work .
It is based on study of processes
sequence and their flow on machines toimplement best possible line balancing, i-e; also called Chain Production.
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Muda (Waste)1.Over-production
2.Motion (of operator or machine)3. Waiting (of operator or machine)4.Conveyance5.Processing itself 6.Inventory
7.Correction (rework)
Muri (Overburden)
Mura (Inconsistency)
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The German word literally means Clock and refers maximum time allowed to
produce a product .Takt Time is defined as:
T= T a/ T dWhere:
Ta = Net Available Time to Work eg. [minutes of work / day]Td = Total demand (Customer Demand) eg. [unitsproduced / day]T = TAKT Time eg. [minutes of work / unit produced]
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It stands for First In First Out and refersto the inventory system where what comes
in first is handled first, what comes in nextwaits until the first is finished .
An effective way of Inventory Management
to ensure smooth flow of inventory with datewise traceability to avoid stock fromdeterioration and going abnormally excess
and also en effective tool of JIT/Pull System.
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Kaizen = Change for Better
5S. = Work DisciplineGemba = Activity Place
Genchi Genbutsu = Go & See The Problem
Obeya = Monitoring Room
Poka Yoke = Mistake Proofing
Jidoka = Automization
Andon = Visual Control
Kanban/Pull System = Signal for Production
Muda, Mura, Muri = Waste/Unevenness/Overburden
Heijunka = Line Balancing
FIFO = First In First Out
Takt Time = Production Time
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Japanese Management Tools begins withsimple Kaizens and results into an Industry
with Work Inducing Environment, OptimallyEffective Production with Zero Defect Ratioand Efficient Utilization of Machines & Manpower and ultimately with continual
upward trend of profitability and downwardtrend of losses.
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Thank You