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Transcript of Kaizen v.2
Training and Implementation What is Kaizen? Kai = Change Zen = Good Kaizen = Continual Improvement Where did kaizen come from? During World War II the United States War Department developed the Training Within Industry (TWI) program to help train the new factory workers who replaced men who had enlisted. TWI programs included Job Instruction (standard work) and Job Methods (process improvement) After World War II, American occupation forces brought TWI experts to Japan to assist in rebuilding. These methods sparked the kaizen revolution in Japan, which led to the Toyota production system that changed the auto industry. Today, kaizen is used by companies worldwide, in industries from manufacturing to healthcare to public utilities. And now, Goodwill! How does it work? Ideas + Experience + Knowledge and Tools = Continuous Improvement Kaizen Is Working Smarter, Not Harder Job Security and Opportunities "We won't have enough hours for our clients!" "Are you saying that we're doing it wrong now?" "We won't be as flexible!" "We tried that before and it didn't work!" "We don't do things that way here." "It's too radical a change." Safety Quality Efficiency Kaizen Isn't Eliminating Jobs Productivity Before Safety One Person in Charge of Quality The way we've always done it Kaizen Effects? Employee Turnover Production Revenue Expenses Supply Costs Before After Event Rules 1 2 4 5 6 Cell phones off! No rank among us; one person, one vote Change is good; more change is better. Maintain a positive attitude - no blame! There are no dumb questions. There is no substitute for hard work. Cellular Production Equipment and workstations are arranged close together and in sequence of the processing steps. The production cell is
U-shaped to bring the end point as close as possible to the beginning point. A production cell is the people, equipment, and space required for production of similar items. Which items can be produced together? Multi-Skilled Operators When equipment is arranged in a process flow, operators may need to learn how to perform different tasks or use different equipment. Cross-training enables employees to perform different tasks and take full responsibility for a process. Working in Teams A group of people have more creative potential and energy than any one person alone! The primary job of people working together in a cell is to maintain a smooth flow LEGO Factory Exercise Space 7 Deadly Wastes Transportation Handling donations more than once
Moving goods long distances
Fix with point of use storage 4 Questions
What is Value?
To whom is value most important?
What’s the most valuable space in our production room? Why?
How can we maximize value? Value of Space Inventory Storage of WIP and raw
Fix with one-piece flow, push to floor Motion Excessive bending, lifting, stretching, turning
Fix with cellular work areas, point of use Waiting Waiting for tools, supervisor, maintenance, etc
Fix with point of use storage, cellular work areas Overproduction Multiple category sorts (i.e. toys, books, shoes)
Fix with one-piece flow! Overprocessing Too much time spent cleaning or trying to fix items Defects Fix with reduced storage and handling Process Flow There are 3 things we do with donations.
Only 1 adds value! Process flow maps 5S Establishing basic working conditions is the first step to cellular production Sort Remove all items not in use regularly
WIP Scrub Thoroughly clean everything
tools Straighten "A place for everything, and everything in its place."
Arrange needed items so they are easy to use, find, and put away for future use.
Point of use. Standardize Create 5 minutes drills.
Update SOPs and work instructions
Develop new standard work for cleaning based off the scrub
What items need to be cleaned daily? Weekly? Monthly? Sustain Complete 5 minute drills.
Complete weekly audits.
Complete 30 day list.
Kaizen means continually improve! 5S Game Put it to work! Break into teams and design your perfect cell. Complete 5S audits of major areas. Kelly Slavens and Jillian Gowen