Date post: | 20-Jan-2015 |
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KM 1
KAIZEN ManagementCharacteristics of
Japanese Production Systems
KM 2
Continuous improvement
KAI-ZEN
V: Green walking
KM 3
What is Industry ?
ProductsServices
Industry
Input Output
Man-powerMachinesMaterialsMethods(4M’s)
TechnologySkill
KM 4
Q, C, D
Evaluation of the output ?
Q: QualityC: CostD: Delivery
Industry
Input Output
KAIZENaction
KM 5
KAIZEN is a corrective action
KAIZEN is a feedback
Industry
Input Output
KAIZENaction
KM 6
KAIZEN is a Japanese word
改 : change 善 : better
KM 7
Definition of KAIZEN
KM 8
1. A selection of better means or a change of current method for achieving an objective.
The Japan HR Association
Definitions of KAIZEN
2. An accumulation of small changes
KM 9
How do farmers pack How do farmers pack oranges?oranges?
KM 10
I need help.
KM 11
Productivity: 1 net per min.
KM 12
KM 13
Productivity: 5 nets per min. with 2 workers
KM 14
Can you think of a better method to pack oranges?
A selection of better means ora change of current method for achieving an objective.
KM 15
Productivity: 5 nets per min. with 1 worker
KM 16
1. A selection of better means or a change of current method for achieving an objective.
The Japan HR Association
Definitions of KAIZEN
2. An accumulation of small changes
KM 17
Chopsticks
KM 18
Children hold their chopsticks improperly
KM 19
KM 20Training
… but still difficult to use
KM 21
Soft paddings (Japanese fish paste)
… for some children, balancing the chopsticks is difficult
KM 22
KM 23
Training chopsticks
KM 24
KM 25
KAIZEN is a continuous improvement
Continuous = again and again
KM 26
Question
KM 27
- I picked up a garbage and put it in a trashcan.
- I wiped the windows and made them clean.
- I used a mop to clean the gasoline left on the floor.
KAIZEN is a small change to make something better.
Where is a division between our jobs and KAIZEN?
KM 28
A waitress was working at a restaurant in Tokyo
KM 29
A small change of a method (approach)
Any way to pick up the mop?Any way to store the mop?Any way to carry the mop?
KAIZEN is a small change
KM 30
KM 31
KM 32
KM 33
toothbrush
KM 34
Swatter
KM 35
tweezers
KM 36
KM 37
Improvement by changing methods
How do we change methods?
KM 38
KAIZEN Steps
KM 39KAIZEN Steps
KM 40KAIZEN Steps Review
KM 41
EliminationRemove this sliding door
What is the use of the sliding doors?
KM 42
Before After
Why are shoe box doors needed?
1
KM 43
Before After
Why is the toilet cover needed?
KM 44ToiletsCDG(Paris) Frankfurt
Hong Kong Tokyo
KM 45
Before
After
No sleeves down-jacket is easy to work
KM 46
Reduce the number of lights
ReduceA fluorescent light bulb was removed.
KM 47
Before
Why two bricks?
KM 48
Parking Lot
KM 49
AfterBefore
One brick is enough to stop a car
1
KM 50
Zebra Zone
1
KM 51
Before
After
Side lines of the zebra zone are removed.
1
KM 52
Before After
Long or short brush part?
KM 53
toothbrushes
KM 54
Ribbon waving?
Change
Visual Management
KM 55
KM 56
Pinwheelturns around
Visual Management
KM 57
Before
After
The hollow about the key hole smoothes the key movement.
1
KM 58
Before
After
To oil the pan, a small teapot is more convenient than a ladle.
KM 59
KM 60
Before
After
Stairways at the railway station should have signs of up and down.
KM 61
At JR Kurume StationAt JR Kurume StationAt JR Kurume StationAt JR Kurume Station
KM 62
KM 63
Rush Hour
KM 64
Before
After
KM 65
Hanging Straps in JR trains
KM 66
Hanging strap in Hanging strap in Hong Kong subwaysHong Kong subways
The Japan HR Association
KM 67
Suggestion Systemvs.
KAIZEN Suggestion System
KM 68
Suggestion SystemYou suggest your ideas, and I will
examine them and implement some of your ideas later.
KM 69
Suggestion System Concept
Rew
ard
Idea
Idea
KM 70
KAIZEN Suggestion System
KAIZEN
sheet
Implemented KAIZEN ideas must be submitted
KM 71
Workers’ responsibility
Workers’ responsibility
Management responsibility
Management responsibility
Suggestion System
KAIZEN Suggestion System
generation Idea
KM 72
Suggestion SystemPropose improvement ideas for any
activity in the company.
KAIZEN Suggestion SystemPropose only improvement ideas which will improve your own work.
KM 73
KAIZEN Memo 1
KM 74
AOTS KAIZEN
KM 75
AOTS KAIZEN
KM 76Reward
For an excellent KAIZEN, a large amount of reward is given (5000 yen, 10000 yen, 50000 yen)
KM 77
Award Payment for Each KAIZEN Suggestion (2008)
18
24
110
109
163
83
11
10
0 50 100 150 200
0
1-99
100-299
300-499
500-999
1000-2999
3000-4999
5000+
Jp
n Y
en
Surveyed 528 companies
Average 385 yen
KM 78
88.7%1
Implemented suggestions
All suggestions
Among (527) companies,
Total number of employees
Employees who suggested at lease one idea
74.4%
2008
KM 79
1. Small change
2. Medium change
3. Big change
(KAIZEN)
(Small group activities)
(Innovation)
--- By individual effort, a better way of proceeding a job is considered. (Idea creation)
--- By group effort, a better way is proposed by following predetermined steps (or rule).
--- By investments in new technology or equipment, dramatic alterations are achieved.
Different styles of change
2
KM 80
Process
ChangeTool Change
Tomato Juice
KM 81
Nikkei News, Nov. 22,1997
Newspaper Article
KM 82
Hydroponics CultivationHydroponics Cultivation
6000 tomatoes6000 tomatoes
1http://www.arigat.net/kandoh.html
KM 83
Material
ChangeProcess
ChangeTool Change
Tomato Juice
2
Man-powerMachinesMaterialsMethods
(4M’s)
Industry
Input Output
KAIZENaction
KM 84
Breakthrough
Status quo
Management
Staff
Floor people
Two Attitudes
KM 85
KAIZEN
Statu
s quo
Innova
tion
KAIZEN
Statu
s quo
Management
Staff
Floor people
Management
Staff
Floor people
Innova
tion
Japanese firms
Non-Japanese firms
KM 86
Fin