Pillar - 2 Kaizen


INTRODUCTION:

Kaizen is a Japanese word, which is combination of two words Kai and Zen. Kai intends to change or Modify., and Zen intends to improve or much better. Basically, Kaizen means small improvement bit carried out on a continual basis and involves all the people in the organization. Kaizen needs no or little investment. The Principle behind kaizen is that is a large number of small improvement are more effective than a few improvement of large value.


The Key element of Kaizen are quality, efforts and involvement all employee, willingness to change and communication.

Kaizen


The objective of this pillar is to maximize efficiency by eliminating waste and manufacturing losses. Kaizen pursue efficient equipment, operator and material and energy utilization and aims at achieving substantial savings. TPM categories manufacturing losses into sixteen losses.

Sixteen Major Losses in an Organization

Categories
Losses
Losses that affect equipment efficiency
    1.     Breakdown losses
    2.    Set up/Adjustment losses
    3.    Cutting tool losses
    4.    Startup and Shutdown losses
    5.    Minor stoppage/idling losses
    6.    Defective/reworking losses
    7.    Slow cycle losses
    8.    Schedule downtime losses
Losses that affect human work  efficiency
    9.    Management Losses
    10. Line balance losses
    11. Operator skill losses
    12. Logistic Losses
    13. Inspection ,measurement and adjustment losses
Losses that affect resource utilization
    14. Energy Losses
    15. Consumable material losses
    16. Material Yield losses

Kaizen Principle
1. Practice idea of zero loss in each  circle of action

2. Pursue to achieve cost reduction target in every resource.

3. Improve overall plant equipment effectiveness

4. Use the PM analysis as tool for eliminating losses

5. Use tool of kaizen effectively

TOOL Uses in Kaizen

  • PM analysis


  • Why-why analysis
  • Summary of Losses
  • Kaizen register
  • Kaizen summary sheet

Foundation of Kaizen method

The Kaizen method is based on

  • Team work
  • Personal Discipline
  • Improved moral
  • Quality circle
  • Suggestions for Improvement