KAIZEN MANAGEMENT SISTEM Lukic Ivana 728\07 Lukic Ivana 728\07

What is Kaizen Management Syistem ? KMS is... KMS is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership.... a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. Toyota company Toyota company

What is Kaizen Management System ?  Kaizen is a Japanese philosophy that focuses on continuous improvement throughout all aspects of life.  When applied to the workplace,as a Kaizen Management System Kaizen activities continually improve all functions of a business, from manufacturing to management.  By improving standardized activities and processes, Kaizen aims to eliminate waste.

Translation  In Japanese this is pronounced "kaizen".  改 "kai" means "change" or "the action to correct".  善 "zen" means "good". 善  The word Kaizen means "continuous improvement".

History  Kaizen was first implemented in several Japanese businesses during the country's recovery after World War II, including Toyota, and has since spread out to businesses throughout the world.  This method became famous by the book of Masaaki Imai “Kaizen: The Key to Japan's Competitive Success.”

Kaizen as a reason of Japanese businesses success  In business Kaizen encompasses many of the components of Japanese businesses that have been seen as a part of their success.  Quality circles, automation, waste categories, suggestion systems, just-in-time delivery, Kanban and 5S are all included within the Kaizen system of running a business.

The Process The quick and easy kaizen process works as follows: 1. The employee identifies a problem, waste, or an opportunity for improvement and writes it down. 2. The employee develops an improvement idea and discusses it with his or her supervisor. 3. The supervisor reviews the idea within 24 hours and encourages immediate action. 4. The employee implements the idea. If a larger improvement idea is approved, the employee should take leadership to implement the idea. 5. The idea is written up on a simple form in less than three minutes. 6. Supervisor posts the form to share with and stimulate others and recognizes the accomplishment.

5S 5S 1.Standardize2.Sort3.Straighten4.Sweep5.Self-discipline

Waste Categories and 9 Wastes To Be Eliminated 1. Work-in-process. Stocking items not immediately needed 2. Quality. Producing defective products. 3. Facilities. Having idle machinery and breakdowns, taking too long for setup. 4. Expenses. Overinvesting for required output. 5. Indirect labor. Excess personnel due to bad indirect labor system. 6. Talent. Employing people for jobs that can be mechanized or assigned to less skilled people. 7. Motion. Not working according to the best work standards. 8. Product Design. Producing products with more functions than necessary. 9. New-product run-up. Making a slow start in stabilizing the production of a new product.

Three Key Characteristics 1.Permanent method changes. Change the method. Once the change is made, you can’t go back to the old way of doing things. 2.Continuous flow of small ideas. The smaller ideas, the better. Kaizen is small ideas. 3.Immediate local implementation. Be realistic. Kaizen is done within realist or practical constraints.

Kaizen Time In some Canon plants, the foremen are told to set aside the half-hour as Kaizen Time – time to do nothing but thinking improvement in the workshop. The foremen use this period to identify problems and work on Kaizen programs. Factories are advised not to hold meetings during this 30-minute period, and foremen should not even answer the telephone then. In some Canon plants, the foremen are told to set aside the half-hour as Kaizen Time – time to do nothing but thinking improvement in the workshop. The foremen use this period to identify problems and work on Kaizen programs. Factories are advised not to hold meetings during this 30-minute period, and foremen should not even answer the telephone then.

The 3 Evils of Meetings.

Benefits  Kaizen Management Sistem empowers employees, enriches the work experience and brings out the best in every person.  Serves as a barometer of leadership.  Kaizen helps eliminate or reduce wastes and improves quality, safety, cost structures, delivery, environments, product and customer service.