Kaizen

Under the guidance of: Presented By:

Ravinder Kumar Aishna Negi
Executive Director
Indian Centre for Research and Manufacturing Aishray Suryawanshi
Excellence Amandeep Singh
Ashutosh Bhat
Mayank Roy
• Kaizen ( 改 善 ), is the Japanese word for “Continuous Improvement". In business, kaizen refers to
activities that continuously improve all functions and involve all employees from the CEO to the
assembly line workers. It has been applied in healthcare, textile, manufacturing, life-coaching,
government, banking, and other industries.
• Kaizen is a lean manufacturing tool that improves quality, productivity, safety and workplace culture by
focusing on applying small changes that result in major improvement over time.
• Types of Kaizen • Key elements of kaizen
1. Gemba Kaizen: Gemba means the place where products are 1. Team work
manufactured. Appling kaizen in Gemba 2. Discipline
2. Kaizen Blitz: It is rapid improvement. The concept is to 3. Improved morale
identify and remove waste quickly. 4. Quality circles
3. Mini Kaizen: Improvements day by day and minute by 5. Suggestion for improvements
minute on the part of all employees.
• PQCDSM
1. Productivity
2. Quality& Quantity
3. Cost & Cleanliness
4. Delivery
5. Safety & Sustainability
6. Morale
Continuous Improvement

THE KAISEN WAY PDCA Applied

• Approach 1: Aadhar came to define one's personal identity.
• Approach 2: It got connected to PAN Card, SIM, Voter Card, Bank Accounts and become more useful than earlier.
• Approach 3: Further Improvement was done.
HOW?
• It is now able to ensure that all your documents are safe at one place via Digi locker.
• KAIZEN is effectively applied at various Stages to improve and add value to its existence.
Industrial Shop Floor Design
Industrial Shop Floor Design

ADVANTAGES :

• Material needed at station is available at hand distance.

• Rack is designed to reduce the waste movement .
• Trolley is designed to reduce the over processing of store
person
Industrial Shop Floor Design

For production of 200 pieces daily 1000 seconds are saved which are
equal to 16 minutes .

Monthly average savings = 8.33 Hrs.

Kaizen in motorsport?

Cylinder head production:

• 67 days of production time
• Muda of material transport
• Plant layout
• Process optimization

Composites:
• Reduction in chassis lead time
• 42 individual steps optimized to 28
• Personalized analysis
• More testing time
• Quality control
The Kaizen Pit stop Was it worth?
• Time reduction
-80% time in aero design
-90% physical assembly time(3weeks to 2 days)
• Improved car performance
• Cost reduction
-60% cost spent for searching design processes
-48% cost for administering engineering change
request

During 2008 preseason testing, Toyota driver

Jarno Trulli recorded the fastest time,
track length: 4.655 kilometer,
Lap time: 1 minute 20.801 seconds,
Advanced Transportation Layout

• Traffic free and Signal free

1. Traffic jams are very less
2. No need of traffic signals
3. Continuous flow
4. Time saving
5. Accident free
6. Kaizen of money, energy,
space, time.
Conclusion
• It’s an idea for improvement
• Minimize wastage
• Max. Utilization of time
• Supports team work with positive attitude
• Necessity not choice