Tài liệu Kaizen Preparation pdf

31/01/14 nhóm chuyên giaHO CHI MINH UNIVERSITY OF TECHNOLOGY FACULTY OF MACHINE INDUSTRIAL SYSTEM ENGINEERING KAIZEN MASTER NGUYEN NHU PHONG GROUP 13 LUU THANH DAT 20600456 DO MINH HOA

31/01/14 nhóm chuyên gia

HO CHI MINH UNIVERSITY OF TECHNOLOGY

FACULTY OF MACHINE INDUSTRIAL SYSTEM ENGINEERING

KAIZEN

MASTER NGUYEN NHU PHONG GROUP 13

LUU THANH DAT 20600456

DO MINH HOANG 20600778

What does Kaizen Mean?

 “Kai” means “Change”

 “Zen” means “for the better”

 Small incremental improvements

 Improvements add up over time

What is a Kaizen Event?

Continuous Improvement

Event

Dedicated Resources

Specific Goals

Short time frame

Also known as Kaizen Blitz

(lightning fast improvement )

Why Use Kaizen?

2

3

4

Taiichi Ohno’s 7 Wastes

 A short burst of intense activity & effort

(can range in hours to days)

 Emphasis on action over analysis

 Focused on improving the Value Stream

and achieving flow

 Driven to resolving a specific problem or

achieving a specific goal

What is a Kaizen Workshop?

What is a Kaizen Workshop?

A Kaizen Workshop is Characterized by

A focus on an area or process to achieve a

specific goal

Includes a team that is empowered to make

changes

Team make-up should include: Operators,

Maintenance, Outside Eyes, and a process owner

Supported by management with Money, Time.

1 Define the opportunity

2 Form & train the team

hand

3 Set goals / collect baseline data

look like?

4 Leader & team responsibilities

Kaizen Preparation

How Are Kaizen Teams Formed?

 Team composition & training is critical to

the success of the team

 Composition should reflect the diversity of

the work center

 A team generally consists of 6-10 people

 Each member will be chosen to perform a

specific role – everybody works

Do It Again

Kaizen

Identify Waste

Plan Counter-measures

Reality Check

Make Changes

Celebrate

Measure Results

Make this the Standard

Document Reality

Verify Change

Start Here

Kaizen Cycle

Six Basic Rules of Kaizen

Tools for Kaizen Blitz Projects

1.Benchmarking

2.Pareto Charts

3.Cause and Effect diagrams

4.Brainstorming

5.Process Mapping

6.Spaghetti Diagrams

7.Internal vs External time/steps

8.Root Cause Analysis (5 Whys)

16

Chicago Manufacturing Center

What is the goal of an Event?

Improve an area of the business

Process Waste Reduction

Space Reduction

Labor Efficiency

Quality or Mistake Proofing

Output Improvement

Manageable

Pick items that can be done right away

Employee Involvement

What happens during an event?

Planning

Select project & team leader

Communicate with target areas

Select team members, define scope & goals

Write work plan/charter

Confirm commitments & gather some data

Re-communicate with target areas

What happens during an event?

Week 4 – Event Week

Training for event

Map & assess current state

Determine improvements,

implement

Pilot changes

What happens during an event?

Weeks 5, 6 & 7 – Follow up

Prioritize open action items

Report to management & core team

Open Items

Achievement of goals

Additional event if necessary

Close out project & document

Archive work plan

Scan all data collected

Everyone and Everything Wins

Front line staff

Better process

Ideas for change

“Being listened to and

allowed to shape the

process I work in”

Organisation

Key indicators improved

Quality Cost Delivery Safety

Customers

Increased Satisfaction

Better quality Better predictability

Lower costs

Questions & Answers