DP-005 ELEMENTS OF WASTE & KAIZEN.pptx

CERTIFIED LEAN SIX SIGMA DEFINE PHASE  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in pro...

CERTIFIED LEAN SIX SIGMA DEFINE PHASE  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in process performance improvement is to be through the use of the methodologies of Six Sigma, Lean and Process Management. By taking this course you will have a well rounded and firm grasp of many of the tools of these methodologies. We firmly believe this is one of the most effective classes you will ever take and it is our commitment to assure that this is the case. ​ DEFINE PHASE ELEMENTS OF WASTE 3MU OF KAIZEN- MUDA, MURA, MURI The basic objective of Kaizen is to eliminate waste called “Muda”. It guides a business in identifying these 3 MUs : 1. Muda (waste) 2. Mura (inconsistency) 3. Muri (strain on people and machines). ELEMENTS OF WASTE  SEVEN COMPONENTS OF WASTE Muda is classified into seven components: Transportation (Conveyance) Inventory Motion Waiting Overprocessing Overproduction Defects (Correction) Sometimes additional forms of muda are added: Skills (Under use of talent) Lack of safety Being Lean means eliminating waste.  TRANSPORTATION Transportation / Conveyance is the unnecessary movement of material and goods. Steps in a process should be located close to each other so movement is minimized. Examples Examples are: are: oo Extra Extra steps steps in in the the process process oo Distance Distance traveled traveled oo Moving Moving paper paper from from place place to to place place Waste of Conveyance is the movement of material.  INVENTORY Inventory is the liability of materials that are bought, invested in and not immediately sold or used. Examples Examples are: are: oo Transactions Transactions not not processed processed oo Bigger Bigger “in “in box” box” than than “out “out box” box” oo Over-ordering Over-ordering materials materials consumed consumed in- in- house house oo Over-ordering Over-ordering raw raw materials materials –– just just in in case case Waste of Inventory is identical to overproduction except that it refers to the waste of acquiring raw material before the exact moment that it is needed.  MOTION Motion is the unnecessary movement of people and equipment. This includes looking for things like documents or parts as well as movement that is straining. Examples Examples are: are: oo Extra Extra steps steps oo Extra Extra data data entry entry oo Having Having to to look look for for something something Waste of Motion examines how people move to ensure that value is added.  WAITING Waiting is nonproductive time due to lack of material, people, or equipment. Can be due to slow or broken machines, material not arriving on time, etc. Examples Examples are: are: oo Processing Processing once once each each month month instead instead of of as as the the work work comes comes in in oo Showing Showing upup on on time time for for aa meeting meeting that that starts starts late late oo Delayed Delayed work work due due to to lack lack of of communication communication from from another another internal internal group group Waste of Waiting is the cost of an idle resource.  OVERPRODUCTION Overproduction is producing more than the next step needs or more than the customer buys. It may be the worst form of waste because it contributes to all the others. Examples Examples are: are: oo Preparing Preparing extra extra reports reports oo Reports Reports not not acted acted upon upon or or even even read read oo Multiple Multiple copies copies in in data data storage storage oo Over-ordering Over-ordering materials materials oo Duplication Duplication of of effort/reports effort/reports Waste of Overproduction relates to the excessive accumulation of work-in- process (WIP) or finished goods inventory.  OVERPROCESSING Overprocessing is tasks, activities and materials that don’t add value. Can be caused by poor product or tool design as well as from not understanding what the customer wants. Examples Examples are: are: oo Sign-offs Sign-offs oo Reports Reports that that contain contain more more information information than than the the customer customer wants wants or or needs needs oo Communications, Communications, reports, reports, emails, emails, contracts, contracts, etc etc that that contain contain more more than than the the necessary necessary points points (briefer (briefer is is better) better) oo Voice Voice mails mails that that are are too too long long Waste of Overprocessing relates to over-processing anything that may not be adding value in the eyes of the customer.  DEFECTS Defects are materials that have been damaged or made incorrectly, or work that needs to be repaired, replaced, or redone due to mistakes Examples are: o Products that do not meet the quality standards o Services that are delivered late, incomplete, or with errors o Processes that generate errors, rework, scrap, or overproduction Any rework or scrap represents a substantial cost to organizations. Any of these costs include quarantining inventory, re-inspecting, loss of capacity, and rescheduling.  5S – THE BASICS 5S is a process designed to organize the workplace, keep it neat and clean, maintain standardized conditions and instill the discipline required to enable each individual to achieve and maintain a world class work environment. Seiri - Put things in order Seiton - Proper Arrangement Seiso – Clean Seiketsu – Purity Shitsuke - Commitment 5S – THE BASICS DEFINE PHASE KAIZEN 改善  KAIZEN 改善 DEFINITION KAIZEN KAI ZEN Change is/ for Good Change Good Changing for the Better Kaizen is a Japanese philosophy that believes “change is good”. “Kai” means change and “zen” means good. This translates to improving the bad points or making them better. In business settings, Kaizen is also a strategic tool that brings about continuous improvement, in terms of increased productivity, superior quality, lower costs, efficient processes, increased safety, and better customer experience. KAIZEN 改善 CHANGE FOR BETTER ” Kaizen is everyday improvement, everybody improvement, everywhere improvement.” Masaaki Imai THE CORE OF KAIZEN  BENEFITS OF KAIZEN Following are some of the benefits you can achieve through Kaizen: 1. Improved Productivity 2. Immediate Troubleshooting 3. Waste Reduction 4. Optimum Utilization 5. Improved Teamwork 6. Improved Communication 7. Better Quality 8. Cost Reductions 9. Better Delivery 10. Improved Safety 11. Increase staff Morale  KAIZEN 5S FRAMEWORK To support continuous improvement, Kaizen theorists recommend practicing 5S which will lead to standardized processes, better time management, improved work culture, and an increase in employee satisfaction.  KAIZEN PRINCIPLES: SUMMARY Team Effort Implementing Kaizen is not just the job of one person or higher-ups in the management but involves each and every member. Good Processes Kaizen believes that good processes bring good results. If any department is performing poorly, it’s the process and not the people that are at fault. Focus on small, continuous changes Kaizen practitioners believe that small, continuous changes bring much better results than a few drastic, big-level changes. See it to believe it Kaizen practice tells you to visit the place of operation to see firsthand the problems experienced, and processes followed. Elimination of waste The basic objective of Kaizen is to eliminate waste called “Muda”. 3MU OF KAIZEN- MUDA, MURA, MURI The basic objective of Kaizen is to eliminate waste called “Muda”. It guides a business in identifying these 3 MUs : 1. Muda (waste) 2. Mura (inconsistency) 3. Muri (strain on people and machines). STEPS OF CONTIOUOUS IMPROVEMENT  IMPLEMENTING KAIZEN The system for implementing Kaizen is called the PDCA Cycle, an iterative model of change comprising four stages: 1. Plan 2. Do 3. Check 4. Act. It is a continuous activity that has to be repeated again and again. This model is also known as the Deming cycle, Shewhart cycle, and plan–do–study–act (PDSA) model. KAIZEN 改善 ACTION PL AN IMPLEMENTING KAIZEN EXAMPLES OF KAIZEN 改善  29 THANK FOR YOUR ATTENTION!!! YOU