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T O T A LQ U A L I T YM A N A G E M E N T S KAIZENC O N T I N U O U SI M P R O V E M E N TI ST H ERESULTOFCONTINUOUSINVOLVEMENTOleh :D e b r i n a P. A n d r i a n iTe k n i k I n d u s t r iUniversitas Brawijayaþ debrina@ub.ac.id
OTLINKaizen- An IntroductionWhat Is KaizenFeatures Of KaizenPhases In KaizenBenefits Of KaizenContents Of An OperationWhat Is Obvious Waste?Workplace OrganizationWorkflow – Line BalancingTraditional Method Vs Kaizen10 Ground Rules For Kaizen5 ‘S’ In KAIZENPit Falls In ina.lecture.ub.ac.id2
KAIZEN- ANINTRODUCTIONMasaaki Imai isknown as thedeveloper of Kaizen.01/04/15www.debrina.lecture.ub.ac.id3
WHATISKAIZEN01/04/15www.debrina.lecture.ub.ac.id4
WHAT IS KAIZEN?KAIZENLow Cost01/04/15ContinuousImprovementKaizen denotescontinuous improvement.Kaizen aims to eliminateall wastes in businessprocesses throughstandardization in theprocesses and activitiesof a business entity.Change making andresult monitoring makeKaizen highly effective.www.debrina.lecture.ub.ac.id5
WHAT IS KAIZEN?EvaluateImplementPlan andDesignAssess/Reassess01/04/15Kaizen activities thataddress issues over aperiod of one week hadbecome the industry normand they had been namedas ‘Kaizen events’.These small models areused to understandproblems and issues in thebusiness processes, arriveat solutions, and applythem to improve theprocesses and eliminatewastes.www.debrina.lecture.ub.ac.id6
WHAT IS KAIZEN?¡ So basically kaizen is small incremental changesmade for improving productivity and minimizingwaste.¡ 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 toevaluate the job as to the best way to get the job done.§ Kaizen must be approached in such a way that no one isblamed and that the best process is put into place.01/04/15www.debrina.lecture.ub.ac.id7
FEATURES OF KAIZENWidely applicable Can be used in both manufacturing and nonmanufacturing environmentsHighly effective &results oriented. Kaizen events will generate quick results, Measurableresults, Establish the baseline, and measure the change!!!A LearningExperience Every member of a Kaizen Team will walk away from theevent learning something new! !Team based &cross functional Team members can be from various functions of thebusiness. Top management participation is encouraged.01/04/15www.debrina.lecture.ub.ac.id8
PHASES INKAIZEN01/04/15www.debrina.lecture.ub.ac.id9
THESE STEPS ARE SHORTEN INTO :A.) Select an EventB.) Plan an EventC.) Implement an EventD.) Follow-up to an Event01/04/15www.debrina.lecture.ub.ac.id10
BENEFITS OF KAIZEN¡ Kaizen Reduces Waste- likeinventory waste, time waste,workers motion¡ Kaizen Improves productquality¡ Results in higher employeemoral and job satisfaction,.¡ Toyota is well-known as oneof the leaders in usingKaizen. In 1999 at one U.S.plant, 7,000 Toyotaemployees submitted over75,000 suggestions, of which99% were implemented.01/04/15www.debrina.lecture.ub.ac.id11
CONTENTS OF AN OPERATION01/04/15www.debrina.lecture.ub.ac.id12
WHAT IS OBVIOUS WASTE?01/04/15www.debrina.lecture.ub.ac.id13
WORKPLACE ORGANIZATION01/04/15www.debrina.lecture.ub.ac.id14
WORKFLOW – LINE BALANCING01/04/15www.debrina.lecture.ub.ac.id15
SMEDQUICK TOOL CHANGEOVER01/04/15www.debrina.lecture.ub.ac.id16
TRADITIONAL METHOD VS KAIZEN01/04/15www.debrina.lecture.ub.ac.id17
10 GROUND RULES FOR KAIZEN01/04/15www.debrina.lecture.ub.ac.id18
5 ‘S’ IN KAIZEN¡ 5S is a method for organizing a workplace,especially a shared workplace (like a shop flooror an office space), and keeping it organized.¡ To take the concept of Kaizen performance to itsultimate level of simplicity, it offered thefollowing "5S" steps§ Sortingkeeping only essential items§ Simplifying§ Sweepingeliminates extra motion .§ Standardizingstandardized work practices§ Sustainingmaintaining and reviewing standards01/04/15keep the workplace cleanwww.debrina.lecture.ub.ac.id19
PIT FALLS IN KAIZEN¡ Resistance to change¡ Lack of proper procedureto implement¡ Too much suggestion maylead to confusion and timewastage01/04/15www.debrina.lecture.ub.ac.id20
SELESAI01/04/15www.debrina.lecture.ub.ac.id21
¡ 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. WHAT IS KAIZEN?
