1.Characteristics ofJapanese Production Systems

2. What is Industry ?Input OutputIndustryMan-powerProductsMachines Services Materials Methods Technology Skill(4Ms)KM 2 3. Evaluation of the output ? Q, C, D Input OutputIndustry Q: Quality C: Cost KAIZEN D: DeliveryactionKM 3 4. KAIZEN is a feedbackInputOutputIndustry KAIZENactionKAIZEN is a corrective actionKM 4 5. Productivity: 1 net per min. KM 5 6. KM 6 7. Productivity: 5 nets per min. with 2 workers KM 7 8. A selection of better means ora change of current methodfor achieving an objective.Can you think of a bettermethod to pack oranges? KM 8 9. Productivity: 5 nets per min. with 1 worker KM 9 10. KAIZEN isa continuous improvement Continuous = again and againKM 10 11. Suggestion Systemvs.KAIZEN Suggestion System KM 11 12. Suggestion SystemYou suggest your ideas, and I will examine them and implement some of your ideaslater. KM 12 13. Suggestion System ConceptKM 13 14. KAIZEN Suggestion System Implemented KAIZEN ideas must be submittedKM 14 15. Suggestion SystemWorkersresponsibility Management responsibilityIdeageneration Workers responsibilityManagementresponsibility KAIZEN Suggestion System KM 15 16. Suggestion SystemPropose improvement ideas for any activity in the company.KAIZEN Suggestion System Propose only improvement ideas whichwill improve your own work.KM 16 17. KAIZEN Memo KM 171 18. AOTS KAIZENKM 18 19. Reward For an excellent KAIZEN, a large amount of reward is given (5000 yen, 10000 yen, 50000 yen)KM 19 20. Award Payment for Each KAIZENSuggestion (2008)0 50100 150200 0 18 1-9924100-299 110Jpn Yen300-499 109500-9991631000-2999833000-4999 11 Average 385 yen 5000+10Surveyed 528 companies KM 20 21. 2008Among (527) companies, Employees who suggested at lease one idea Total number of employees 74.4% Implemented suggestions All suggestions88.7% KM 21 1 22. Different styles of change1. Small change--- By individual effort, a better way of proceeding a job is considered.(KAIZEN) (Idea creation)2. Medium change--- By group effort, a better way isproposed by following (Small group predetermined steps (or rule). activities)3. Big change --- By investments in new technology orequipment, dramatic alterations are (Innovation) achieved. 2 KM 22 23. ProcessChangeTomato Juice KM 23 24. Tomato JuiceProcess MaterialChangeChange Input OutputIndustry Man-power MachinesMaterialsMethodsKAIZENaction (4Ms)2KM 24 25. Two AttitudesManagement BreakthroughStaffFloor peopleStatus quo KM 25 26. Japanese firmsManagementStaffFloor people Non-Japanese firmsManagementStaffFloor peopleKM 26 27. KAIZEN is a Japanese word. Contents 28. Definition of KAIZEN1. better method for achieving an objective.2. An accumulation of small changes. Bricks Bricks3. A corrective action under constraints. 29. Kaizen Objectives Quality Cost Delivery(QCD) 30. 5 S for Kaizen1. Simple2. Small3. Smooth4. Slim5. Smart 31. Kaizen PQCDSEM P-Productivity Q-Quality C-Cost D- Delivery S-Safety E-Environment M-Moral 32. Raise theLower the tabletableA corrective action under constraints 33. You cannot change the tableheight. 34. After KAIZEN Easy to work. Footstool 1 35. You must open 3 doors to start KAIZEN(ProblemIdentification)ImplementationProblem solving(Idea generation)3 36. KAIZEN by EliminationWhy are shoe box doors needed? BeforeAfter 1 37. KAIZEN by EliminationWhy are shoe box doors needed? BeforeAfter 1 38. KAIZEN by ReductionBefore1 39. KAIZEN by Reduction Side lines of the zebra zone are removed.Before After 1 40. KAIZEN by ChangeBefore 1 41. KAIZEN by ChangeThe hollow about the key holesmoothes the key movement. BeforeAfter 1 42. Thank You