FINAL KAIZEN-NeenaSinha

Views:
 
     
 

Presentation Description

No description available.

Comments

Presentation Transcript

PowerPoint Presentation:

Global Operations Management Trends NEENA SINHA

KAIZEN-GENESIS Production Methods:

KAIZEN-GENESIS Production Methods As technology and analysis of production methodology has improved, methods have changed dramatically – what used to be labour intensive production methods are now capital intensive

PowerPoint Presentation:

Where Do You Start - From Top or Bottom? Change Culture First (Conventional way) Change System First (Lean Way) WHAT WE DO VALUES - ATTITUDES BASIC ASSUMPTIONS Lean Enterprise Transformation

PowerPoint Presentation:

Involvement People Systems for the Lean Enterprise Human Resources Management Work Systems Programs Suggestion Programs Kaizen Standardized Work/ Kaizen Responsibility pushed down QC Circles Employee Development Rewards and Recognition Examples Kaizen JIT/JIDOKA Respect for People

'Toyota Production System':

'Toyota Production System' In 1970, 'Toyota Production System' known as TPS was introduced based on the principles of: Jidoka Just-in-time

PowerPoint Presentation:

JIDOKA Jidoka , as practiced at Toyota has several meanings. It may mean "automation with human intelligence"  ( Autonomation ). Jidoka also refers to the practice of stopping a manual line or process when something goes amiss. In one form, Jidoka uses limit switches or devices that shut down a process when: The required number of pieces have been made. A part is defective The mechanism jams.

JUST-IN-TIME:

JUST-IN-TIME Just In Time ( JIT ) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and its associated costs. The process is driven by a series of signals, or Kanban ( カンバン also 看板), that tell production processes to make the next part. Kanban are usually simple visual signals, such as the presence or absence of a part on a shelf. JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency when implemented correctly. New stock is ordered when stock reaches the re-order level. This saves warehouse space and costs...

PowerPoint Presentation:

KAIZEN Based on the Toyota system Masaki Imai introduced Kaizen a team concept that means continuous and incremental improvement at all levels: machine operators, middle manager and even the CEO are part of the process. Kaizen is an umbrella concept covering just-in-time inventory, zero defects, quality circles and suggestion systems etc. Basically, you take a look at your operations and you eliminate everything that’s wasteful.

PowerPoint Presentation:

Kaizen's Starting Point: Setting the Right Mindset & Business Environment not a single day should go by without some kind of improvement being made somewhere in the company customer-driven strategy for improvement - any management activity should eventually lead to increased customer satisfaction quality first, not profit first - an enterprise can prosper only if customers who purchase its products or services are satisfied recognition that any corporation has problems and establishing a corporate culture where everyone can freely admit these problems and suggest improvement problem solving is seen as cross-functional systemic and collaborative approach emphasis on process - establishing a way of thinking oriented at improving processes, and a management system that supports and acknowledges people's process-oriented efforts for improvement

PowerPoint Presentation:

TEIAN Kaizen is controlled; It is not acceptable to let anybody change designs, layouts or standards for some pretended "improvement". Most often Kaizen is controlled by improvement groups and everybody, regardless to rank or position, is encouraged to suggest trough suggestion submiting system ( TEIAN in Japanese). Suggestions will be discussed by authoritative comittee. Suggestions likely to be turned into application are usually rewarded according to the global gain. Improvement idea can be a response to a problem exposed by KAIZEN comittee or come out spontaneously

PowerPoint Presentation:

HUMAN CUSTOMER ORIENTATION QUALITY CONTROL (QC) CIRCLES SUGGESTION SYSTEM DISCIPLINE IN THE WORKPLACE SMALL-GROUP ACTIVITIES COOPERATIVE LABOR-MANAGEMENT RELATIONS QUALITY IMPROVEMENT OPERATIONS AUTONOMATION ROBOTICS ZERO DEFECTS TOTAL PRODUCTIVE MAINTENANCE (TPM) KAMBAN JUST-IN-TIME (JIT) PRODUCTIVITY IMPROVEMENT NEW PRODUCT DEVELOPMENT KAIZEN

MUDA Waste, known as "muda" in Japanese, is everything that does not add value. Muda is the deadly enemy of value creation:

MUDA Waste, known as "muda" in Japanese, is everything that does not add value. Muda is the deadly enemy of value creation Waste of motion; Time delays; Unnecessary transporting and material handling; Making defects; Over processing; Over producing; Storing inventory; and Missed opportunity.

PowerPoint Presentation:

5S AND KAIZEN 5S movement is a determination to organize work place, to keep it neat, to clean, to maintain the discipline to do a good job--They require perseverance and determination. They require constant effort. 5Ss are like a mirror reflecting our attitudes and behavioural patterns . .

PowerPoint Presentation:

5S AND KAIZEN Seiri (整理): tidiness, organization. Refers to the practice of sorting through all the tools, materials, etc., in the work area and keeping only essential items. Everything else is stored or discarded. This leads to fewer hazards and less clutter to interfere with productive work Seiton (整頓): orderliness. Tools, equipment, and materials must be systematically arranged for the easiest and most efficient access. There must be a place for everything, and everything must be in its place Seiso (清掃): cleanliness. Indicates the need to keep the workplace clean as well as neat. Cleaning in Japanese companies is a daily activity. At the end of each shift, the work area is cleaned up and everything is restored to its place. Seiketsu (清潔): standards. Allows for control and consistency. Basic housekeeping standards apply everywhere in the facility. Everyone knows exactly what his or her responsibilities are. House keeping duties are part of regular work routines. Shitsuke (躾): sustaining discipline. Refers to maintaining standards and keeping the facility in safe and efficient order day after day, year after year.

PowerPoint Presentation:

EDWARD DEMING AND CONTINUOUS IMPROVEMENT . P-D-C-A Cycle ACTION CHECK PLAN DO GRASP the SITUATION HYPOTHESIS TRY REFLECT ADJUST

MARUTI UDYOG LTD:

MARUTI UDYOG LTD QUALITY CONTROL (QC) CIRCLES SUGGESTION SYSTEM DISCIPLINE IN THE WORKPLACE SMALL-GROUP ACTIVITIES COOPERATIVE LABOR-MANAGEMENT RELATIONS KAMBAN JUST-IN-TIME (JIT) PRODUCTIVITY IMPROVEMENT ZERO DEFECTS BAJAJ AUTO TOTAL PRODUCTIVE MAINTENANCE (TPM )

PowerPoint Presentation:

At Bajaj Auto, manufacturing operations are characterised by a mix of high volume products from relatively simpler but older facilities and smaller volume products from complex new facilities, thus demanding very high workforce versatility. It is like living in two worlds. Furthermore, ever-increasing quality and cost pressures challenge individual skills and collective effort continuously. In this context TPM's cross-functional, bottom up, empowering, detail oriented, fact based, analytical, approach to be extremely simple and sharply result . KAIZEN AT BAJAJ AUTO

PowerPoint Presentation:

TOTAL PRODUCTIVE MAINTENANCE (TPM ) TPM provokes awkward introspection. For example, previously certain processes continuously yielded 2% defective components. Professor Yamaguchi embarrassed the management team by observing that extraordinary skills were required to ensure such a precise failure rate. It should be much simpler to achieve 100% OK. Needless to say, this was quickly achieved through phenomenon identification, root cause analysis and implementation of not only appropriate counter-measures for immediate correction, but also preventive action for long term sustenance. TPM focuses effort on improvement in PQCDSM (Production, Quality, Cost, Delivery, Safety and Morale) through the elimination of losses

PowerPoint Presentation:

KAIZEN PROCESS EVENT

PowerPoint Presentation:

HONDA MOTOR CORPORATION STRATEGIC LEVEL Assessment of current processes, Work with key customers Their needs Perceptions of current system Map current processes Identify the critical processes bottlenecks obvious to the customers consume disproportionate resources

PowerPoint Presentation:

Kaizen Events These become the subjects for initial Kaizen Events Develop the metrics assess current performance describing the level of improvement provides the resources, in the form of people, time and facilitators

Toyota’s OBEYA :

Toyota’s OBEYA Obeya in Japanese means simply “big room.” At Toyota it has become a major project management tool, used especially in product development, to enhance effective and timely communication. Similar in concept to traditional “war rooms,” an Obeya will contain highly visual charts and graphs depicting program timing, milestones and progress to date and countermeasures to existing timing or technical problems.  Project leaders will have desks in the Obeya or site of Kaizen Events at appropriate points in the program timing.  The purpose is to ensure project success and shorten the plan-do-check-act cycle.

PowerPoint Presentation:

KAIZEN EVENTS New system is run and documented Floor space occupied by the process Operators required per day Distance traveled by an order Work-in-Process Inventory (in piece count) Setup, as measured in minutes Quality Recommendations generated Safety improvements implemented Prepare presentation to top management Friday morning Describe projects Identify the changes introduced Improvements achieved Present “Action List” issues that the team could not address but which should be considered to improve the overall performance of the process other

PowerPoint Presentation:

Assembly line Work teams Assembly line Work teams worker Kaizen system Means “continuous improvement”. Work teams evolving along a production chain. Workers become members of a production chain that, even if still working on an assembly line, is more flexible

PowerPoint Presentation:

Kaizen Benefits Problems are identified at source, and resolved. Small improvements which are realized can add up to major benefits for the business Improvements, which lead to changes in the business quality, cost and delivery of products, mean a greater level of customer satisfaction, and business growth. By involving employees in looking at their environment to bring about change, results in improved morale as people begin to find work easier and more enjoyable.

PowerPoint Presentation:

Flexible Manufacturing System A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility which allows the system to react in the case of changes, whether predicted or unpredicted. This flexibility is generally considered to fall into two categories, within which are numerous other subcategories. The first category, machine flexibility, covers the system's ability to be changed to produce new product types, and ability to change the order of operations executed on a part. The second category of flexibility within an FMS is called routing flexibility, which consists of the ability to use multiple machines to perform the same operation on a part, as well as the system's ability to absorb large-scale changes, such as in volume, capacity, or capability.

Six Sigma:

Six Sigma Six Sigma is a methodology to manage process variations that cause defects, defined as unacceptable deviation from the mean or target; and to systematically work towards managing variation to eliminate those defects. The objective of Six Sigma is to deliver high performance, reliability, and value to the end customer. It was pioneered by Bill Smith at Motorola in 1986 and was originally defined as a metric for measuring defects and improving quality; and a methodology to reduce defect levels below 3.4 Defects Per (one) Million Opportunities (DPMO). Six Sigma has now grown beyond defect control. Six Sigma is a registered service mark and trademark of Motorola , Inc. Motorola has reported over US$17 billion in savings from Six Sigma to date.

Mass Customization :

Mass Customization Mass customization , in marketing , manufacturing , and management , is the use of flexible computer-aided manufacturing systems to produce custom output. Those systems combine the low unit costs of mass production processes with the flexibility of individual customization. Tseng and Jiao define mass customization as "producing goods and services to meet individual customer's needs with near mass production efficiency"

PowerPoint Presentation:

ANY QUESTIONS?

authorStream Live Help