KAIZEN Management

KAIZEN Management
(Supplementary materials)

Graduate School of Asia-Pacific Studies Waseda University, Tokyo Professor Dr. Seiichi FUJITA

fujitas@waseda.jp http://www.wiaps.waseda.ac.jp/user/fujita/

Copyright S. Fujita

KAIZEN Management

Industrial 1

Industrial 2

What are these?

Industrial Collection
The Japan HR Association
Bolt Nut Washer

The Japan HR Association

The Japan HR Association

Industrial 3

Industrial 4

Washer (Before KAIZEN)

It is difficult to pick up a washer placed on a table.

Washer (After KAIZEN 1)

Curved table

Thin sponge
The Japan HR Association The Japan HR Association

Industrial 5

Industrial 6

Washer (After KAIZEN 2)

Drawer (Before KAIZEN)

Workers had to bend to read the label of the tool drawer. Well
Wrench

10 cm thick sponge

Label

The Japan HR Association

The Japan HR Association

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KAIZEN Management

Industrial 7

Industrial 8

Drawer (After KAIZEN 1)

The tool drawers were lifted up, but another problem occurred.
Easy to look.
Difficult to pick up

Drawer (After KAIZEN 2)

Names of tools were listed in a table. It was posted on a wall.
Heres a wrench

The Japan HR Association

The Japan HR Association

Industrial 9

Industrial 10

Flag Pulley (Before KAIZEN)

The metal pulley located at the top of the pole made noise.
Sque ak !
Oil is needed. Noisy

Picture of Flag Pole

The Japan HR Association

The Japan HR Association

Industrial 11

Industrial 12

Flag Pulley (After KAIZEN)

A vinyl bag in which oil was contained was tied with rope. The bag would break at the pulley.
Oil
Vinyl bag

Time Table (Before KAIZEN)

When a fluorescent lamp burn out, it had to be replaced by two workers.
Hey! Are you done?

Wait a second.
The Japan HR Association The Japan HR Association

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KAIZEN Management

Industrial 13

Industrial 14

Time Table (After KAIZEN 1)

The worker who supported the cover was replaced by a pole.

Time Table (After KAIZEN 2)

A handy tool with a sharp edge was made.
Simple Handy Safe

Ah!

A flexible vise Sharp edge

Rubber coating
The Japan HR Association

The Japan HR Association

Industrial 15

Industrial 16

Tank (Before KAIZEN)

When drawing out the water, the hose stuck to the bottom of the tank frequently.

Tank (After KAIZEN)

A T-shaped joint was attached to the tip of the hose.

The Japan HR Association

The Japan HR Association

Industrial 17

Industrial 18

Bumper Car (Before KAIZEN)

A worker found a nut on the floor. Which bumper car lost it?

Bumper Car (After KAIZEN)

Each car, as well as the nut, was painted with a same color.
Same color

The Japan HR Association

The Japan HR Association

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KAIZEN Management

Industrial 19

Industrial 20

Bulb (Before KAIZEN)

The hand was too big to reach the burnt out bulb.
Uh m !

Bulb (After KAIZEN)

Push a rubber hose to replace the bulb. Rubber Easy
hose
installation and removal

The Japan HR Association

The Japan HR Association

Industrial 21

Industrial 22

Bulb (Application)
A hose is used to pick up a cap of the tire at Japanese gas stations. This way
It was difficult to move the bulb cap.

Oyster (Before KAIZEN)

In winter, workers requested a pair of gloves to keep hands warm. However, a use of rubber gloves made the work more difficult.

never loses the cap.

The Japan HR Association

The Japan HR Association

Industrial 23

Industrial 24

Oyster (After KAIZEN)

Tips of thumb and forefinger of the rubber gloves were cut off.

Bucket (Before KAIZEN)

At the company dormitory, buckets with water were placed at several locations for fire prevention. Many people were stumbling over the buckets and the floor was flooded.

The Japan HR Association

The Japan HR Association

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KAIZEN Management

Industrial 25

Bucket (After KAIZEN)

The water was packed with a transparent vinyl plastic bag, and it was placed in the bucket. This could prevent the water from flooding and could be usable in case of a fire.

The Japan HR Association

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KAIZEN Management

World 1

World 2

Egypt

World Collection

FUJITA

Egypt Pyramids

World 3

World 4

Highway (Before KAIZEN)

Difficult to take a left turn.

by El-Kashef Osman
(Egypt)

World 5

World 6

Highway (After KAIZEN)

U-turn zone makes left turns easy.
U-turn zone

Sink (Before KAIZEN)

Product Shape
90 Side View

by El-Kashef Osman
(Egypt)

by Sayed Ibrahim (Egypt)

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KAIZEN Management

World 7

World 8

Sink (After KAIZEN) Mongolia

by Sayed Ibrahim (Egypt)

Mongolia Green

World 9

Mongolia Summer (June 96)

World 10

Mongolia Winter (November 98)

World 11

World 12

Sheep (Before KAIZEN)

One must stay to push the sheeps head into the water.

by Dorjsursn (Mongolia)

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KAIZEN Management

World 13

World 14

Sheep (After KAIZEN)

By making a ditch at the bottom of the pool, the sheeps head goes underwater by itself.

Knitting (Before KAIZEN)

Yarn balls are rolling and mixed up.

by Dorjsursn (Mongolia)

by Munkhtsetseg
(Mongolia)

World 15

World 16

Knitting (Before KAIZEN)

Yarn balls are placed in a container.

Ghana

by Munkhtsetseg (Mongolia)

Picture Ghana 1

World 17

Picture Ghana 2

World 18

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KAIZEN Management

World 19

World 20

Carry Water (Before

KAIZEN)

Ghana Pic.

by Harun (Ghana)

World 21

World 22

Carry Water (After KAIZEN)

He fetches water directly into bucket on his head.

Goat (Before KAIZEN)

When an owner calls them back home, a goat will head home, but a sheep will not.

by Harun (Ghana)

by Asare Bedman
(Ghana)

World 23

World 24

Goat (After KAIZEN)

By tying both animals, they both came back home together.

Sri Lanka
by Asare Bedman
(Ghana)

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KAIZEN Management

World 25

World 26

Sri Lanka Fruits 1

Sri Lanka Fruits 2

What is this fruit ?

Kandy, Sri Lanka

World 27

World 28

Problem (India) What is written on the red signal?

1. STOP 2. WAIT 3. RELAX

India

4. DONT DRIVE 5. DONT WALK

World 29

World 30

Answer 1 (India)

Answer 2 (India)

1. STOP 2. WAIT 3. RELAX 4. DONT DRIVE 5. DONT WALK

1. STOP 2. WAIT 3. RELAX 4. DONT DRIVE 5. DONT WALK

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KAIZEN Management

World 31

Qatar What is this?

Picture Qatar 1

World 32

The Japan HR Association

World 33

World 34

Picture Qatar 2

What can you buy from this vending machine?

The Japan HR Association

Japan

World 35

World 36

Answer: EGGS

China
(Taiwan)

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KAIZEN Management

World 37

World 38

Expel Fly (Before KAIZEN)

Expel Fly (After KAIZEN)

Water balloon magnifies the flys image to frighten the fly.

by Liao Chien-Hung
(R.O.C.)

by Liao Chien-Hung (R.O.C.)

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KAIZEN Management

Reference books
Many reference books are available. You may search Amazon.com by putting one of the following keywords: KAIZEN, 5S, JIT or Toyota. Some reference books which are recommended to have a deep understanding for KAIZEN Management are listed as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. Tozawa Bunji, Norman Bodok The Idea Generator: Quick and Easy Kaizen PCS Press 2001 Imai Masaaki Kaizen (Kyzen): the key to Japans competitive success McGraw Pub. 1986 Japan Human Relations Association The improvement engine: creativity & innovation through employee involvement: The Kaizen Teian system Productivity Press, 1995 Osada Takashi The 5Ss: five keys to a total quality environment Asian Productivity Organization, 1995 Hirano Hiroyuki Putting 5S to work: a practical step-by-step approach PHP Institute, 1993 Shingo Shigeo A revolution in manufacturing: the SMED system Productivity Press, 1985 Shingo Shigeo A study of the Toyota production system from an industrial engineering viewpoint Productivity Press, 1989 Christensen Clayton The innovators Dilemma Harper Collins, 2003 Utterback James Mastering the Dynamics of Innovation: How companies can seize opportunities inn the face of technological change Harvard Business School Press, 1994

10. Sugiyama Tomoo 5S approach to improvement PHP Institute, 1998 11. Ohno Taiichi Toyota production system: Beyond large-scale production Productivity Press, 1988 12. Shingo Shigeo Non-stock production: The Shingo System for Continuous Improvement Productivity Press, 1995 13. Liker Jeffrey The Toyota Way: 14 Management Principles from the Worlds Greatest Manufacturer, McGraw-Hill 2004 14. Robinson, Alan (Editor) The continuous improvement in Operations: A systematic Approach to Waste Reduction Productivity Press, 1991 15. Japan HR Association KAIZEN Teian I: Development systems for Continuous Improvement through Employee Suggestions Productivity Press 1992 16. Japan HR Association KAIZEN Teian II: Guiding Continuous Improvement through Employee Suggestions Productivity Press, 1992 17. Japan HR Association The Idea Book: Improvement through TEI (Total Employee Involvement) Productivity Press 18. Hirano, H. JIT Factory Revolution: A Pictorial Guide to Factory Design of the Future Productivity Press. ISBN 0-915299-44-5 19. Majima, I. The shift to JIT: How people make the difference Productivity Press. ISBN0-9915299-93-3 20. Monden, Y. Toyota Production Systems Institute of Industrial Engineers. 1983

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KAIZEN Management

KAIZEN awareness check 1

1. A driving force to KAIZEN activities is a. Monetary award b. Problem consciousness c. Workers' motivation d. Management skill "Innovation" (in contrast to KAIZEN) is a. A short cut approach b. A new fashion c. A good management d. A big change KAIZEN is defined as a. An accumulation of small changes b. A quick way of changing your work c. A method to increase productivity d. A good manner KAIZEN steps are defined as a. Change - Eliminate - Reduce b. Reduce - Change - Eliminate c. Eliminate - Reduce - Change d. Simplify - Combine - Remove Approximately what percent of Japanese companies seems to adopt KAIZEN suggestion system? a. 40% b. 70% c. 90% d. 100% Japanese production managers believe that the most important issue/concept for production management in 1990's is a. Reduction of production lead-time b. Integration of production and sales c. Improvement of customer service d. Marketing research

2.

3.

4.

5.

6.

7. An original idea of JIT came from a. Drive-in theater b. Fast food restaurant c. Supermarket d. Gas station 8. KANBAN which is used in JIT production systems is a. A tool to supply products to customers b. A tool to fill up parts which are used. c. A sign for alarm d. A billboard

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9.

"Poka-Yoke (Fool proof) devices" are a. Protection devices from earthquake and typhoons b. Devices which increase production volume c. Devices which motivates production workers d. Devices which eliminate operator's careless mistakes A purpose of minimum inventory (stockless production) is a. To find out (or visualize) problems to be improved. b. To enhance management capability for the risk. c. To make inventory control easy. d. To save inventory cost. The 5S stands for a. Five times more satisfaction b. Five keys for success c. Five Japanese words with an initial S d. Five factors for a work improvement The average time allowed to fetch (search, find and bring back) a hammer is a. 10 seconds b. 30 seconds c. 60 seconds d. 90 seconds For a facility investment, approximately how much is used for cleanliness? a. 80% of the investment cost b. 60% of the investment cost c. 30% of the investment cost d. 10% of the investment cost The essence of "Seiso (cleaning)" is a. An inspection b. Picking up a garbage c. A search d. A standardization

KAIZEN Management

10.

11.

12.

13.

14.

15. The essence of " Shitsuke (self-discipline) " is a. To set up a rule b. To let people greet to each other c. A communication d. A habit formation

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KAIZEN Management

KAIZEN awareness check 2

[KAIZEN] 1. A driving force to KAIZEN activities is a. Monetary award b. Problem consciousness c. Workers' motivation d. Management skill "Innovation" (in contrast to KAIZEN) is a. A short cut approach b. A new fashion c. A good management d. A big change KAIZEN is defined as a. An accumulation of small changes b. A quick way of changing your work c. A method to increase productivity d. A good manner What does KAIZEN change? a. Change - Eliminate - Reduce b. Reduce - Change - Eliminate c. Eliminate - Reduce - Change d. Simplify - Combine Remove KAIZEN steps are defined as a. Change - Eliminate - Reduce b. Reduce - Change - Eliminate c. Eliminate - Reduce - Change d. Simplify - Combine - Remove For KAIZEN suggestion system, what type of ideas must be submitted? a. Ideas to change company policy b. Ideas to change your own work c. Ideas to improve profit d. Ideas to improve management style Approximately what percent of Japanese companies seems to adopt KAIZEN suggestion system? a. 40% b. 70% c. 90% d. 100%

2.

3.

4.

5.

6.

7.

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[JIT] 1.

KAIZEN Management

Japanese production managers believe that the most important issue/concept for production management in 1990's is a. Reduction of production lead-time b. Integration of production and sales c. Improvement of customer service d. Marketing research

2. An original idea of JIT came from a. Drive-in theater b. Fast food restaurant c. Supermarket d. Gas station 3. A factor which makes your production schedule difficult is a. A demand fluctuation b. A marketing strategy c. An employee involvement d. A bonus incentives KANBAN which is used in JIT production systems is e. A tool to supply products to customers f. A tool to fill up parts which are used. g. A sign for alarm h. A billboard An aim of one-piece flow is a. A high productivity b. A high flexibility c. A low defective rate d. A low cost "Poka-Yoke (Fool proof) devices" are a. Protection devices from earthquake and typhoons b. Devices which increase production volume c. Devices which motivates production workers d. Devices which eliminate operator's careless mistakes A purpose of minimum inventory (stockless production) is a. To find out (or visualize) problems to be improved. b. To enhance management capability for the risk. c. To make inventory control easy. d. To save inventory cost.

4.

5.

6.

7.

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[5S] 1.

KAIZEN Management
The 5S stands for a. Five times more satisfaction b. Five keys for success c. Five Japanese words with an initial S d. Five factors for a work improvement The purpose of theRed Tag Movement is a. To distinguish the necessary things and unnecessary things b. To clean up a workplace c. To decorate products d. To find the shortest way of achieving an objective The average time allowed to fetch (search, find and bring back) a hammer is a. 10 seconds b. 30 seconds c. 60 seconds d. 90 seconds For a facility investment, approximately how much is used for cleanliness? a. 80% of the investment cost b. 60% of the investment cost c. 30% of the investment cost d. 10% of the investment cost The essence of "Seiso (cleaning)" is a. An inspection b. Picking up a garbage c. A search d. A standardization A problemis defined as a. Homework assignment b. Objects which you must attack c. A gap between ideal state and current state d. Something which you can buy at supermarket The essence of " Shitsuke (self-discipline) " is a. To set up a rule b. To let people greet to each other c. A communication d. A habit formation The value offixed-position photographic approach is a. Employees involvement b. Customer satisfaction c. Job rotation d. Quality improvement

2.

3.

4.

5.

6.

7.

8.

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KAIZEN Management

Instructions:
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Draw sketches of Before KAIZEN and After KAIZEN Use a DARK black pen or a THICK pencil

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