The Kaizen Process of Continuous Improvement

Introduction

KAIZEN is a Japanese word meaning gradual and orderly, continuous improvement. The KAIZEN business strategy involves everyone in an organization working together to make improvements 'without large capital investments'. KAIZEN is a culture of sustained continuous improvement focusing on eliminating waste in all systems and processes of an organization. It is everybody’s business to continuously improve their ability to meet expectations of high quality, low cost and on-time delivery. KAIZEN transforms companies into 'Superior Global Competitors'.

Objective

• Understand the KAIZEN concept.
• Learn the practice of KAIZEN at all levels.
• Motivates the whole workforce through empowerment and ownership of ideas.
• Learn how to identify, analyze and tackle problems for continuous improvement.
• Learn how to implement KAIZEN.
• Learn some of the basic and advance tools and techniques of Kaizen.
• Enables companies to make more effective use of resources.
• Help companies to progress along the route for world class performance.

Methodology

Course methodology includes a combination of Classroom sessions; LCD projector, video presentation as well as work-related application will be used.

Course Content

 

1. Overview: The Theory behind Kaizen

Since Kaizen is often interpreted differently by the companies that use it. Participants will be introducing to the variations represent the components of Kaizen that become associated with various objectives:

• Manufacturing best practices 
• Tools for eliminating waste 
• Understand and apply the Quality Planning tools
• Identify and apply the Quality Control tools
• Identify and utilize Quality Improvement tools
• How to carry out their Process Capability studies
• Understand Basic Statistics and Basic Anova
• Creating standards 
• A co-operative environment 
• A creative workforce 
• Lean manufacturing 

2. Theory 

• What is Kaizen? 
• Why Kaizen? 
• What is Waste? 
• Value-Added, Lean & Flexible Manufacturing 
• People: The Heart and Mind of Kaizen 
• The Kaizen Principles 
• The Ten Basic Tips for Kaizen Activities 

3. Lean Techniques 

• 5S 
• Single Minute Exchange of Die (SMED) also known as Set-up Reduction
• Total Productive Maintenance (TPM)
• Standard Work 

4. Kaizen Tool

• Pareto Charts 
• Ishikawa (Fishbone) Diagram 
• Histograms
• Check-Sheets
• Five “Why?” Root Cause Analysis: Getting to the root 
• Brainstorming and Consensus Decision Making: Facilitation Techniques
• Process Mapping

    

5. Scatter Plots

6. Statistical Process Control

7. Gantt Charting

 

8. Kaizen Event Planning