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QUALITY ENGINEERING: KAIZEN TECHNIQUE

ADAM Firdaus, Amirul HAZIQ, KANG Wee Shuien, Muhammad HAQKIKI. QUALITY ENGINEERING: KAIZEN TECHNIQUE. PRESENTATION OUTLINE. Introduction How It Works Related Categories Examples in Industries Advantages / Disadvantages Conclusion. INTRODUCTION. Definition:

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QUALITY ENGINEERING: KAIZEN TECHNIQUE

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  1. ADAM Firdaus, Amirul HAZIQ, KANG Wee Shuien, Muhammad HAQKIKI QUALITY ENGINEERING:KAIZEN TECHNIQUE

  2. PRESENTATION OUTLINE Introduction How It Works Related Categories Examples in Industries Advantages / Disadvantages Conclusion

  3. INTRODUCTION • Definition: • 改 (change) + 善 (good) • Therefore, KAIZEN means “continuous improvement” • What is it? • Performance improvement method used by companies • Why? • Foster strong relationship between manager & employee, • Minimal implementation cost

  4. HOW IT WORKS? • Focus: • Improvement of productivity, efficiency, quality and business excellence • Principles of Kaizen Technique: • Good processes bring good results • Go see for yourself to grasp the current situation • Speak with data, manage by facts • Take action to contain and correct root causes of problems • Work as a team

  5. HOW IT WORKS? • Kaizen Technique can be implemented in various stages of system: • Total Quality Management • Totally Productive Maintenance • Suggestion System • Just In Time (Production System) • Organisation Politics Management • Activities in Small Groups

  6. RELATED CATEGORIES

  7. Three Pillars Of Kaizen Technique Housekeeping – 5s Waste elimination Standardisation - PDCA

  8. Housekeeping – 5S Five words to represent the concept of good maintenance

  9. Waste Elimination Elimination of waste in process is an important pillar under Kaizen concept

  10. Muda Any non-value adding activity will be considered as muda in Japan In Kaizen philosophy, there are seven types of waste: • Overproduction • Inventory • Defects • Motion • Processing • Waiting • Transportation

  11. Overproduction – production of large batches, change of customer demand Inventory – excessive finished products being kept in inventory Defects – rejection, more inspection work Motion – unnecessary motion of a person in workplace Processing – problems occur in processing Waiting – time being spent on waiting during operation Transportation – moving materials adding no value, damage occur

  12. Standardisation Plan-do-check-act (PDCA) is a four step management method for continuous improvement under Kaizen technique

  13. All team members in all parts of the organisation are continuously looking for ways to improve operations, and people at every level in the company support this process of improvement.One of the principles that support Kaizen is the TPS methods. (Thinking People System) Applications in Industry "No process can ever be declared perfect but it can always be improved"

  14. Examples 1 3P’s Toyota Problem Solving The Toyota Production System invites team members to think about the process and make timely decisions in order to keep it running smoothly, rather than merely operating like machines. This involvement creates responsibility for the success of the process, Morale ( ) and Quality ( ) FACTS:  About 3,000 proposals for improvements are made each year at Toyota Material Handling Europe’s production sites. Number of submitted suggestions is more important rather than the impacts and effects of the suggestions.

  15. Examples 2

  16. Improvement Efficiency Of Parts Picking Works At The Warehouse. The collision of two picking carts were often happened when they go out from part storage picking lane to the main lane, thus resulted in decrease in work efficiency There was a suggestion from a worker that engaged in the picking work to ensure eyesight by leaving the shelf without storing parts. The collisions were decreased with implementing this suggestion. This kind suggestion is possible only by the workers who know the work place well. Manager cannot make this type of suggestions.

  17. Advantages Kaizen technique • Have to bring an immense change in mind set and style of functioning – difficult at very initial point • Low-cost implementation, • Gives participants (employees) a sense of purpose, • Delegates responsibility to participants (employees), • Harbours group centered-activity, • Encourages teamwork, • Reduce need for inspection, • Focus for improvement is returned to needs for customer. Disadvantages

  18. CONCLUSION • Internationally acknowledged as methods of continuous improvement through small steps, of the economical results of companies, • generate the major multiplication of the company’s profit while constituting a secure way to obtain the clients’ loyalty. • Best methods of performance improvement within companies, • Allow the increase of efficiency and productivity while ensuring a pleasant organizational climate (5S),

  19. Thank you

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