Kaizen Philosophy

What is Kaizen?
• Kaizen means ”Continuous Improvement".

• Kaizen is based on making little changes on a regular

basis- always improving productivity, safety and

effectiveness, and reducing waste.

• Kaizen philosophy - "do it better, make it better,

improve it even if it ain't broke, because if we don't,

we can't compete with those who do."

Types of Kaizen
• Normal work done by different method
• No pending work for want of time
• Eliminate waste
• Elimination of any activity not adding value to the end
product
• Safety improvement
• Housekeeping
• Elimination of 3 D work (Dirty, Difficult & Dangerous)
Kaizen Tips
• MISER ( Merge, Improve, Simplify, Eliminate, Reduce) to

make the work easier, better, faster with lesser efforts

• Use Common Sense & not Common Knowledge

• Never accept the Status Quo

• Identify Waste in an area where you think none exists

• Listen to your method of working in silence

• Reduce waiting
The 10 Commandments of Improvement
I. Abandon fixed ideas.
II. Think of ways to make it possible.
III. No excuses needed.
IV. Go for the simple solution, not the perfect one.
V. Correct mistakes right away.
VI. Use your wits, not your wallet.
VII. Problems are opportunities.
VIII. Repeat ‘why?’ five times.
IX. Seek ideas from many people.
X. There is no end to improvement.
Kaizen Eye
Constituents of Kaizen

• Theme Problem

• Analysis Idea

• Countermeasure Result

• Benefit
Theme
• Reduce
• Set up loss, Operating Motion loss, Start up loss,
Tool change loss.....
• Eliminate
• Defect, tool breakage, rework, unsafe condition.....
• Increase
• MTBF, output.....
Example
• Eliminate

• To eliminate Minor stops due to spurious alarm in

AMS CNC machine in Cylinder Head line

Problem
• Use 5W1H to describe the problem

• What is the event ?

• When does the event happen ?

• Where does the event happen ?

• Who is involved ?

• Which is the machine / stage involved ?

• How does the event happen ?

Example: Problem

• On (Which) AMS VMC machine in (Where) Engine

PU (Who) operator operates the cycle and

(How) servomotor switches off or on, (When)

sometimes giving rise to (What) spurious servo alarms

leading to stoppage of machine.

 Contactors
CNC System on door
Analysis

• To carry out time analysis for set up, tool

change, MTTR.....

• To find out root cause for Defects, Rework,

breakdown, OML......
Example - Set up time analysis
ACTIVITY Before After
Removal Sec. (min.) Sec.
1) Remove 1st gear mandrel 0 25
Adjustment
2) Adjust wheel slide & 840(14) 0
Register job
3) Machine job & adjust size 720(12) 0
in steps
4) Adjust the final size 240(4) 0
Fixing
7) Fix 2nd gear mandrel 0 25
TOTAL 1800(30) 50
Root cause Analysis - using Why-Why

• Purpose - “Why-Why” Analysis helps to structure the

brainstorming towards finding the root causes.

• When to Use it - When the team needs to explore

possible root causes and represent them on a single

diagram.
How to Use it
• Ask "Why" - i.e. what are the first level of causes of the
problem?
• Write each cause on the diagram.
• For each cause, ask "Why" again and write the
answers in the next column, linked to the previous
answer.
• Keep asking "Why" until no more answers can be
suggested. (Generally the last ‘Why’ is indicated by a
stupid answer)
How to Use it

• Use the causes listed, especially those on the last level

of the diagram, to generate possible solutions.

• Review data for evidence of which causes are most

important; gather fresh data if necessary.

Example - Why-Why Analysis (AMS machine)
Q - Why machine has stopped
A - There is a spurious servo alarm
Q - Why there is a spurious servo alarm
A - There is electrical noise in the supply
Q - Why there is electrical noise
A - Contactors are mounted close to CNC system
Q - Why contactors are mounted close to CNC system
Key word - Close
Examples of root causes (Key word)
• Poka Coolant

• Less Friction Big

• Fully Long

• Many Bolts Cannot detect

• Chip Difficult

• Loose Gap

• Close
Idea
• Opposite to root cause (Key Word)

• Poka Poka Yoke

• Coolant No coolant
• Less Friction More friction
• Fully Partially
• Long Short
• Many Bolts Less bolts
• Chip No chip
• Difficult Easy
• Loose Tight
• Gap No gap
• Close Far
Countermeasure

• Providing or Changing

• Action oriented

• In engineering industry approximately 90% of

countermeasures will fall into these two categories.

Countermeasure - (AMS)
• Provided a separate electrical panel for the contactors
on coolant tank to take them far from the CNC system

Contactors in separate
panel away from CNC
Result
It always relates to the theme & falls into one of the

following category

• Reduce time

• Reduce frequency

• Eliminate

• Increase life

Example - Eliminated minor stops on AMS machine

Benefit

It has to be always linked to P or C

• Increase Production

• Reduce Cost

Example - Production increased from 90 per shift to 91

per shift
Horizontal Deployment

• Identify opportunities for application of the idea on

other machines, cells, PU or location

• Make time plan for implementation if it is in your area

• Implement

• Upload in Knowledge Management Portal for

communication to all the plants

Kaizen Examples
Thank You