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1 T O T A L Q U A L I T Y M A N A G E M E N T + S KAIZEN CONTINUOUS IMPROVEMENT IS THE RESULT OF CONTINUOUS INVOLVEMENT Oleh : Debrina P. Andriani Teknik Industri Universitas Brawijaya þ debrina@ub.ac.id

2 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 O U T L I N E 01/04/15 2

3 KAIZEN- AN INTRODUCTION Masaaki Imai is known as the developer of Kaizen. 01/04/15 3

4 WHAT IS KAIZEN 01/04/15 4

5 WHAT IS KAIZEN? Low Cost KAIZEN Continuous Improvement 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. 01/04/15 5

6 WHAT IS KAIZEN? Assess/ Reassess Plan and Design Implement Evaluate Kaizen activities that address issues over a period of one week had become the industry norm and they had been named as Kaizen events. These small models are used to understand problems and issues in the business processes, arrive at solutions, and apply them to improve the processes and eliminate wastes. 01/04/15 6

7 WHAT IS KAIZEN? 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. 01/04/15 7

8 FEATURES OF KAIZEN Widely applicable Can be used in both manufacturing and nonmanufacturing environments Highly effective & results oriented. A Learning Experience Team based & cross functional Kaizen events will generate quick results, Measurable results, Establish the baseline, and measure the change!!! Every member of a Kaizen Team will walk away from the event learning something new!! Team members can be from various functions of the business. Top management participation is encouraged. 01/04/15 8

9 PHASES IN KAIZEN 01/04/15 9

10 THESE STEPS ARE SHORTEN INTO : A.) Select an Event B.) Plan an Event C.) Implement an Event D.) Follow-up to an Event 01/04/

11 BENEFITS OF KAIZEN 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. 01/04/

12 CONTENTS OF AN OPERATION 01/04/

13 WHAT IS OBVIOUS WASTE? 01/04/

14 WORKPLACE ORGANIZATION 01/04/

15 WORKFLOW LINE BALANCING 01/04/

16 SMED QUICK TOOL CHANGEOVER 01/04/

17 TRADITIONAL METHOD VS KAIZEN 01/04/

18 10 GROUND RULES FOR KAIZEN 01/04/

19 5 S IN KAIZEN 5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized. To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following "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 01/04/

20 PIT FALLS IN KAIZEN Resistance to change Lack of proper procedure to implement Too much suggestion may lead to confusion and time wastage 01/04/

21 SELESAI 01/04/