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T O T A L
Q U A L I T Y
M A N A G E M E N T
11|KAIZEN
C O N T I N U O U S
I M P R O V E M E N T
I S
T H E
RESULT
OF
CONTINUOUS
INVOLVEMENT
Oleh :
D e b r i n a P. A n d r i a n i
Te k n i k I n d u s t r i
Universitas Brawijaya
þ d e b r i n a @ u b . a c . i d
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¡  Kaizen- An Introduction
¡  What Is Kaizen
¡  Features Of Kaizen
¡  Phases In Kaizen
¡  Benefits Of Kaizen
¡  Contents Of An Operation
¡  What Is Obvious Waste?
¡  Workplace Organization
¡  Workflow – Line Balancing
¡  SMED - Quick Tool Changeover
¡  Traditional Method Vs Kaizen
¡  10 Ground Rules For Kaizen
¡  5 ‘S’ In KAIZEN
¡  Pit Falls In Kaizen
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KAIZEN- AN
INTRODUCTION
Masaaki Imai is
known as the
developer of Kaizen.
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WHAT
IS
KAIZEN
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WHAT IS KAIZEN?
KAIZEN
Low Cost
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Continuous Improvement
Kaizen denotes
continuous improvement.
Kaizen aims to eliminate
all wastes in business
processes through
standardization in the
processes and activities
of a business entity.
Change making and
result monitoring make
Kaizen highly effective.
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WHAT IS KAIZEN?
Evaluate
Implement
Plan and
Design
Assess/
Reassess
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Kaizen activities that
address issues over a
period of one week had
become the industry norm
and they had been named
as ‘Kaizen events’.
These small models are
used to understand
problems and issues in the
business processes, arrive
at solutions, and apply
them to improve the
processes and eliminate
wastes.
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WHAT IS KAIZEN?
¡ So basically kaizen is small incremental changes
made for improving productivity and minimizing
waste.
¡ 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.
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FEATURES OF KAIZEN
Widely applicable
•  Can be used in both manufacturing and nonmanufacturing environments
Highly effective &
results oriented.
•  Kaizen events will generate quick results, Measurable
results, Establish the baseline, and measure the change!!!
A Learning
Experience
•  Every member of a Kaizen Team will walk away from the
event learning something new! !
Team based &
cross functional
•  Team members can be from various functions of the
business. Top management participation is encouraged.
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PHASES IN
KAIZEN
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THESE STEPS ARE SHORTEN INTO :
A.) Select an Event
B.) Plan an Event
C.) Implement an Event
D.) Follow-up to an Event
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BENEFITS OF KAIZEN
¡  Kaizen Reduces Waste- like
inventory waste, time waste,
workers motion
¡  Kaizen Improves product
quality
¡  Results in higher employee
moral and job satisfaction,
and lower turn-over.
¡  Toyota is well-known as one
of the leaders in using
Kaizen. In 1999 at one U.S.
plant, 7,000 Toyota
employees submitted over
75,000 suggestions, of which
99% were implemented.
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CONTENTS OF AN OPERATION
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WHAT IS OBVIOUS WASTE?
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WORKPLACE ORGANIZATION
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WORKFLOW – LINE BALANCING
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SMED
QUICK TOOL CHANGEOVER
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TRADITIONAL METHOD VS KAIZEN
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10 GROUND RULES FOR KAIZEN
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5 ‘S’ IN KAIZEN
¡  5S is a method for organizing a workplace,
especially a shared workplace (like a shop floor
or an office space), and keeping it organized.
¡  To take the concept of Kaizen performance to its
ultimate level of simplicity, it offered the
following "5S" steps
§  Sorting
keeping only essential items
§  Simplifying
§  Sweeping
eliminates extra motion .
§  Standardizing
standardized work practices
§  Sustaining
maintaining and reviewing standards
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keep the workplace clean
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PIT FALLS IN KAIZEN
¡ Resistance to change
¡ Lack of proper procedure
to implement
¡ Too much suggestion may
lead to confusion and time
wastage
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SELESAI
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