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JAPANESEANDOTHERPRODUCTIVITY

TECHNIQUESINMANUFACTURING

Kaizen, JIT, Kanban and Poka- Yoke

Submitted to- Prof. Ajit Kurvey

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INDEX

Introduction

Management- Improvement Function

KaizenJIT

Kanban

Poka-yokeBibliography

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INTRODUCTION

Japanese manufacturing techniques generally approach

productivity with the goal of reducing unnecessary

expenses, waste and time, while increasing production

and efficiency.

Many of the modern Japanese manufacturing techniques

were developed after World War II and peaked in the

1980s.

Large companies such as Toyota are credited with

pioneering many of the manufacturing techniques used

by Japanese companies and these techniques have spread

to non-Japanese companies as well, due to their

effectiveness

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IMPROVEMENTFUNCTION- KAIZEN

Kaizen: The Key to Japan's Competitive Success

This method became famous by the book of Masaaki

Imai which meansKAIChange & ZENGood i.e

improvement.

It means works continuously towards revising the

current standards, once they have been mastered, and

establishing higher ones.

Improvement can be broken down between innovation

and Kaizen.

Kaizen signifies small improvements as a result of

coordinated continuous efforts by all employees.

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IMPROVEMENTFUNCTIONKAIZEN(CONTD...) By improving standardized activities and processes,

kaizen aims to eliminate waste as in leanmanufacturing( Toyota Production System )

Kaizen was first implemented in several Japanese

businesses after World War II, influenced in part by

American business and quality management teacherswho visited the country

It is also a process that, when done correctly,

humanizes the workplace, eliminates overly hard work,

and teaches people how to perform experiments ontheir work using the scientific method and how to learn

to spot and eliminate waste in business processes.

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KEYPRACTICES

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Customer Orientat ion Determine the perceptions, needs, and wants of target markets

Satisfy them through the design, communication, pricing

Quali ty Contro l Circ le (QCC) Come together to discuss with the management issues related to either quality

control or improvement in production methods.

Voluntarily meet on a regular basis to identify, analyze and solve their problems.

Disc ip l ine in the work place

Co-operative Labo r Manager Relations . TQM

Functions on the premise that the quality of the products andprocesses is the responsibility of everyone who is involved withthe creation or consumption of the products or services offered bythe organization.

Quali ty Improvement

It is a formal approach to the analysis of performance andsystematic efforts to improve it. There are numerous models used.Some commonly discussed include: PDSA , Six Sigma , CQI,TQM

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Autom at ion and Robot ics

Autonomat ion

Itis

automationwith a human touch

.

If there is a problem the machine can not resolve , the

production is stopped and the human workers look into the

matter and apply countermeasures so that such things do not

happen again .

Kanban Jus t-in-t ime

Zero defects

It tries to bring defects in production to zero .

Total Produ ctive Maintenance the machine operator is thoroughly trained to perform much of

the simple maintenance and fault-finding.

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KAIZENATTOYOTA

There are two kinds of kaizen activities at Toyota:

kaizen made by the supervisory staff and engineers astheir functions,

that made by workers through the quality circles and

suggestion system.

Cost of each of the parts and a standard time for theirproduction.

A maintenance team

An assembly line is divided into about ten segments per

function

A large conveyer installed on the ground level permit

workers to operate

Tasks to carry heavy parts also disappeared by installing

automatic or semi-automatic equipment .

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FEATURESOFKAIZEN

Improvements are based on many small changes

Small improvements are less likely to require major

capital investment.

The ideas come from the talents of the existing

workforce

Continuous improvement in individual performance

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FEATURESOFKAIZEN( CONTD...)

It helps encourage workers, thereby improvingworker motivation

Kaizen is a daily process, the purpose of which

goes beyond simple productivity improvement.

humanizes the workplace, eliminates overly hardwork ("muri"),

Teaches people how to perform experiments ontheir work using the scientific method and how tolearn to spot and eliminate waste in businessprocesses.

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COMPANIESIMPLEMENTINGKAIZEN

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Jit is a strategy used in inventory management.

With JIT strategy companies aim to decrease waste and inventory

costs by receiving goods only when they are needed to produce.JIT inventory mgmt thus increases efficiency and is used by companies

that prefer to keep low inventory levels.

In order for JIT to work corrctly the company must be able to predict

demand for the product and how much inventory will be needed at what

stagesIt has also been described as an approach with the objective of producing

the right part in the right place at the right time.

.

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KEY ELEMENTS OF JIT.

Reduce or eliminate setup times.

Reduce lot sizes.

Reduce lead times.Preventive maintenence.

Flexible workforce.

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ADVANTAGES OF JIT.Lower stock holding means a reduction in storage space which

saves rent and insurance costs As stock is only obtained when it is needed,

working capital is tied up in stock

There is less likelihood of stock perishing ,becoming obsolete or

out of date. Avoids the build-up of unsold finished product that can occur

with sudden changes in demand

Less time is spent on checking and re-working the product

of others as the emphasis is on getting the work right first time

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DISADVANTAGES OF JIT.

There is little room for mistakes as minimal stock is kept for

re-working faulty product

Production is very reliant on suppliers and if stock is

not delivered on time, the whole production schedule can be delayed.

There is no spare finished product available to meet unexpected orders,

because all product is made to meet actual orders

however, JIT is a very responsive method of production

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IMPROVEMENTFUNCTIONKANBAN

Kanban (literally signboard or billboard) is a

scheduling system for lean and just-in-time (JIT)

production. According to its creator, Taiichi Ohno,

kanban is one means through which JIT is achieved

It is a inventory scheduling system that helps

determine what to produce, when to produce it, and

how much to produce

The need to maintain a high rate of improvement

led Toyota to devise the kanban system. Kanbanbecame an effective tool to support the running of

the production system as a whole.

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IMPROVEMENTFUNCTION

KANBAN(CONTD...)

Basic Principles:-

Start with what you do now

Agree to pursue incremental, evolutionary change

Respect the current process, roles, responsibilities &

titles

Leadership at all levels

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IMPROVEMENTFUNCTION

KANBAN(CONTD...)

Kanban cards

Three bin System

Electronic systems

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POKAYOKE

Japanese for mistake-proofingPoka - inadvertent mistake

Yokeprevent

Developed in the 1960s

Either prevents a mistake from

being made or makes the mistakeobvious at a glance

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The cause of defects lie in worker errors, and defects are a

result of neglecting those errorsmistakes will not turn

into defects if worker errors are discovered and eliminated

beforehand - Shingo

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THREETYPESOFINSPECTION

Judgment inspection

Informative inspection

Source inspectionOften Poka Yoke devices

ensure the proper operatingconditions exist prior to actualproduction

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POKAYOKEDEVICECATEGORIES

Prevention device - makeerrors impossible

Detection device - Makeerrors visible to the operator

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CHARACTERISTICSOFGOODPOKAYOKEDEVICES

they are simple and cheapthey are part of the process

they are placed close towhere the mistakes occur

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