...Auburn University | Kaizen | A Simple and Powerful Philosophy | Justin Willette 11/16/2012 | Table of Contents Introduction3 The Meaning of Kaizen3 History4 Goals of Kaizen4 Tools of Kaizen6 Implementing Kaizen7 An Example of Kaizen9 Other Applications11 Conclusion12 Bibliography13 INTRODUCTION Kaizen is an idea with humble beginnings that has taken hold of the manufacturing world and grown to become a powerful tool that can be harnessed to become a dominate player in the industrial world. The philosophy of Kaizen is a simple idea. It aims to continually make small changes anywhere it can in a process in order to improve the overall process. Kaizen focuses on a few key concepts to create a lean manufacturing system. The Kaizen system includes many components such as quality circles, just-in-time delivery, 5S, kanban, and many more. These tools are utilized to implement Kaizen. The Kaizen philosophy has been applied to many different industries all around the world. THE MEANING OF KAIZEN The Business Dictionary defines Kaizen as the “Japanese term for a gradual approach to ever higher standards in quality enhancement and waste reduction, through small but continual improvements involving everyone from the chief executive to the lowest level workers.” ("Kaizen") There are a few key phrases in this definition that truly illustrates the Kaizen way of thinking. First, this definition states that Kaizen is an approach to achieve...
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...MAF 635 MANAGEMENT ACCOUNTING & PERFORMANCE EVALUATION SMA PROJECT: KAIZEN COSTING PREPARED BY: FATNIN SYAIDA BINTI RAHIMI AZMAN 2012240862 NUR HANIS BINTI ABU BAKAR 2012407426 NURUL NAJIAH BINTI ABU BAKAR 2012883308 GROUP: AC 220 8A Table of Contents No. | Contents | Pages | 1 | Acknowledgement | 1 | 2 | Introduction | | | * Definition and Principles of Kaizen | 2 | | * When Target Costing and Kaizen Costing are Linked | 3 | 3 | Kaizen Philosophy | 4 - 7 | 4 | Person Involved | 8 | 5 | Kaizen Advantages | 8 | 6 | Kaizen Disadvantages | 9 | 7 | Conclusion | 9 | 8 | Application to Industry | 10 - 11 | 9 | References | 12 | SUBMITTED TO: NIK MUZARENI BT NIK MOHAMED History of Johnson & Johnson Johnson & Johnson was first found by three brothers, Robert Wood Johnson, James Wood Johnson and Edward Mead Johnson in New Brunswick, New Jersey, U.S. In 1873, the company was named Seabury & Johnson and led by Robert Wood Johnson. It focussed on medical products business with his partner, George Seabury. Robert then hired his brothers, Edward and James to work with the company. Later on, in 1886, the two younger brothers left Seabury & Johnson and formed new company called Johnson & Johnson which is after their names. The company’s logo is actually based on James’s handwriting which can be seen below his photograph. Robert then left Seabury & Johnson and joined his brothers. Basically, the...
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... |Pg. No. | |1 |INTRODUCTION- HISTORY OF KAIZEN |1 | |2 |MAJOR KAIZEN CONCEPTS |3 | |3 |MAJOR KAIZEN SYSTEMS |6 | |4 |GEMBA |8 | |5 |THE FIVE GOLDEN RULES OF GEMBA MANAGEMENT |15 | |6 |MUDA |20 | |7 |KOBETSU KAIZEN |27 | |8 |CASE STUDY-EXCEL INDUSTRIES LIMITED (ROHA) |28 | The Pledge Alone We Are Weak, Together We Are Strong. We Shall Work Together As A Family, In Mutual Trust And Responsibilty. Progress Can Be Attained Only If We Are Ready To Change Ourselves. As The World Moves Forward We Must Keep In Step. The Only Thing Of Importance Is Reality At The Gemba Introduction KAIZEN Japanese term that means continuous improvement, taken...
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...JIT Introduction JIT in time concept was initiated in Japan making the Toyota as its mater piece. JIT is system whether company starts manufacturing/purchasing once the customer orders the good effectively making zero inventories. In other words, in a JIT environment materials are purchased and produced as and when it is needed. The whole idea is based on the phrase provide the goods just in time as promised when the order is placed by the customer. The opposite of the JIT production is known as JIC (Just in case) system where it produces goods for inventory with the intention of having goods just in case a customer places an immediate order. JIT production system identifies the hidden problems in the value chain and reduces the production waste of the system while increasing the throughout (Sales- Raw Material Cost). Even though the JIT system seems to be interesting and less complicated it requires lot of coordination with supply chain to avoid delays in the production schedule. The whole concept of the JIT is differentiated from traditional productions systems using push vs. pull systems ofproduction. The push system of production pushes materials to the next stage of the production irrespective of whether time and resources are needed at the next level of production creating lot of inventories at each level of the production flow. The traditional manufacturing organizations adopt push system where they produce for inventory and work in progress. The pull system of production...
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...Supplier Development at Honda, Nissan and Toyota: Comparative Case Studies of Organizational Capability Enhancement* Mari Sako Professor of Management Studies Said Business School University of Oxford Park End Street Oxford OX1 1HP, UK Email mari.sako@sbs.ox.ac.uk October 2002 * This study was funded by the International Motor Vehicle Program (IMVP), the UK Economic and Social Research Council, and the Japan Foundation. I am grateful to the interviewees at the three automakers and suppliers who gave generously of their time. I also appreciate the comments of many colleagues, and in particular those of Bill Lazonick. Abstract What factors facilitate and constrain the development and replication of organizational capabilities at suppliers? This question is addressed in a comparison of historical case studies at Toyota, Nissan and Honda in Japan. First, as expected, replication difficulty is overcome by enabling companies to share the process of accumulating tacit knowledge. Second, the interdependence in the hierarchy of routines, that constitute organizational capabilities, has led companies to broaden the scope of supplier development. Third, this broadening challenges suppliers to accept buyer companies’ intervention in internal investment decisions, requiring a certain type of corporate governance. It is argued that the boundary of a capability-based organization may go beyond legally distinct units of financial control when firms are subjected to a cumulative process...
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...NATIONAL INSTITUTE OF TECHNOLOGY DURGAPUR A PROJECT REPORT ON “SPOT BURR REDUCTION BY IMPROVING THE WORKABILITY OF SPOT GUN” Submitted in the partial fulfilment of the requirements for the award of the Degree of Bachelor of Technology in Mechanical Engineering Submitted By Mayukh Biswas ( 10/ME/27) Project Work Carried Out at Toyota Kirloskar Motor Private Limited Under the Guidance of Mr. Abhinand S AM Underbody, Weld Shop ( Plant 1 ) Toyota Kirloskar Motor (TKM) NATIONAL INSTITUTE OF TECHNOLOGY DURGAPUR (DEEMED UNIVERSITY) M.G. ROAD, DURGAPUR 713209 CERTIFICATE This is to certify that the Project work entitled “SPOT BURR REDUCTION BY IMPROVING THE WORKABILITY OF SPOT GUN” Carried out by Mayukh Biswas bearing R. No. : 10/ME/27 in partial fulfilment for the award of Bachelor of Technology in Mechanical Engineering of National Institute of Technology, Durgapur. It is certified that all corrections/suggestions indicated for internal assessment have been incorporate in the Report. The project report has been approved as it satisfies the academic requirements in respect of project work prescribed for said Degree. Mr. Abhinand S AM Underbody, Weld Shop (Plant 1) Toyota Kirloskar Motor (TKM) Ms. Mili Mathew HR Learning & Development Toyota Kirloskar Motor (TKM) Acknowledgement It gives me great pleasure to acknowledge the numerous personalities involved in lending their help to make this Project Work titled “ SPOT BURR REDUCTION...
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...Quality Control Quality Control Quality Training Manual Kajohn Hillman 6/23/2014 Table of Contents I. Introduction i. History of quality Management ii. The need for Quality Management II. The Role of Leadership i. Role they play in the success ii. Firms adoption of roles and effects of nonexistent role modeling iii. Monitoring and Metrics within the quality management improvements III. General Quality Strategies and Tools i. Establishing customer expectations ii. Designing quality in iii. Defining metrics iv. Mistake-proofing v. Kaizen vi. Six Sigma IV. Quality Tactics and the Logistics and Supply Chain Functions i. What tools are applicable internally ii. What tools are applicable externally with vendors V. Week 5: Roll-Out i. A communication plan ii. Sequence of steps to get personnel trained iii. Stakeholders on board I. History Of Quality Management The history of quality management and the movement can be traced as far back as medieval times in Europe when craftsmen and tradesmen organized themselves in unions called guilds which predate the 13th century. It wasn’t until the 19th Century when the industrial manufacturers of the world adopted this model of craftsmanship. The system had its emphasis on the inspection process which started in Great Britain during the 1700’s and grew immensely during the Industrial Revolution of the 1800’s. In the 20th century these manufacturers...
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...included Dunlop and Firestone. 2. 2nd Generation Companies - which included MRF, CEAT, Goodyear, and Premier. 3. 3rd Generation Companies - which included Apollo, Vibrant, Modi Rubber, and J.K.Tyres. 4. 4th Generation Companies - includes the companies started after 1970 and also which are yet to start production. Pneumatic Tyres are manufactured according to relatively standardized processes and machinery, in around 450 tire factories in the world. Over 1 billion tyres are manufactured annually, making the tyre industry the majority consumer of natural rubber. Tire factories start with bulk raw materials such as rubber, carbon black, and chemicals and produce numerous specialized components that are assembled and cured. 1.2 HISTORY OF THE TYRE The very first tyres were made of wood, lined with iron. They were used on all carts and wagons thus making the rides very uncomfortable. Then in the mid 1800’s rubber was used in...
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...The history of Six-Sigma The roots of Six Sigma as a measurement standard go back to Carl Frederick Gauss (1777-1885) who introduced the concept of normal curve. Six Sigma as a measurement standard in product variation can be traced back to the 1920´s when Walter Shewhart showed that three sigma, from the mean is the point where a process requires correction. As history would seem to have it, the beginnings of Six Sigma really come from 1979 when an exasperated Motorola executive named Art Sundry said, at a meeting, “The real problem at Motorola is that our quality stinks!”. Apparently, this statement led to series of activities that in turn led to the discovery of the crucial correlation between higher quality and lower development costs in manufacturing products of all kinds. The problem was that the common thought was that quality initiatives simply cost too much money. What Motorola realized is that if these initiatives were done right, improving quality would actually reduce costs. Motorola decided to take the approach that high quality products should actually cost less to produce. Motorola reasoned that the highest quality producer should be the lowest cost producer. THEORETICAL ANALYSIS OF THE CONCEPT OF SIX-SIGMA What is Six-Sigma Six-Sigma has at least three different meanings depending upon the context; there is not one answer to what is Six-Sigma. The first answer to what is Six-Sigma is that it is a management philosophy. Six-Sigma is...
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...STATEMENT OF PURPOSE My family background: My family have five members including myself. My father is manager in Gujarat Alkali and Chem Ltd. He is working in the company since 14/10/1982. My mother, Mrs. she is a homemaker and she likes to do cooking and keep the home neat and tidy. My sister has completed bachelors in Computer Engineering and MS in Computer Science and is currently studying bioinformatics in Colorado, USA. My younger brother is studying in 12th standard of Kaizen School, Vadodara. Academic Profile: I have completed my Bachelor in commerce with subjects - Accounts and Financial Management from MSU, Vadodara in 2010 and Master in commerce with subjects- Finance and Taxation from S.N.D.T Women’s University (Mumbai) in 2012. While doing my master degree, I did projects on topics relating to subjects like Strategic management, Economic and business environment, Financial Management, Corporate Accounting, International Economic Environment, Corporate tax Planning and Management and Financial Auditing and Taxation. Reason I want to pursue PG Diploma - Financial Planning at Centennial College: After finishing my Master in Finance and Taxation, I still to felt the need to focus and narrow down my scope of specialisation to something that really interested me – Financial Planning. In my country, such specialisation is offered as part of larger curriculum but not as the main area of focus. This program at Centennial College is exactly what I was looking...
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...introduce Lean. It took Toyota many years to develop their culture into one of continuous improvement. For organizations that are new to Lean, the effort required will be significant in order to realize the true value associated with Lean principles. Poor planning will almost certainly result in disappointment and leave a strong negative association with any future Lean attempts along with a big investment with little to no return. With a focus on continuous improvement and continuous flow, manufacturing based on pull rather than push demand will assist organizations in becoming Lean. While Lean is a long journey, it can be one that returns significant value to an organization. What follows is a view of the history of Lean, some of the tools such as Value Stream Mapping, Kaizen, etc, along with the expected benefits, potential barriers, critical success factors, and a quick view of Lean at Suncor. Table of Contents 1.1. Introduction 4 1.2. Concepts, Theories, Tools and Techniques 5 1.2.1. The Toyota Production System 5 1.2.2. The Toyota Way 5 1.2.3. Continuous Flow – Pull versus Push 5 1.2.4. Mudda and the...
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...modeling and analysis as well as mathematical optimization to make a positive impact on the environment, society and its own financial success. The principles of lean manufacturing that aid in the elimination of waste have helped the company meet ever increasing customer demands while preserving valuable resources for future generations. The implementation of lean and sustainable manufacturing was aided by the use of discrete event simulation and optimization to overcome deficits in lean’s traditional implementation strategies. Lean and green manufacturing can have a more significant, positive impact on multiple measures of operational performance when implemented concurrently rather than separately. These ideas are demonstrated by three applications. Keywords: lean manufacturing, green manufacturing, case-study, discrete event simulation, optimization 1 Introduction Manufacturers are under tremendous pressure to improve productivity and quality while reducing costs. This has led many organizations to implement the Toyota Production System (TPS), otherwise known as lean manufacturing (Liker, 2004; Womack, 2003). Thus, it seems to be important to gain an understanding of how TPS relates to other methods for improving manufacturing systems including Green A case study of lean, sustainable manufacturing...
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...TOYOTA MOTOR COMPANY: AN IN-DEPTH STUDY OF THE SUCCESS OF THE KAIZEN PHILOSOPHY Toyota Motor Company recently claimed number one spot in global sales in the auto industry. Many practitioners of the “Toyota Way” concur that Toyota is the model company to imitate, but recent years Toyota has seen a decline in their core competence of quality control. Weaknesses to social and environmental fluctuations have had negative effects on Toyota’s continued profitability. Analysis of strategy and execution precedes recommendations for improving Toyota’s implementation of its famed kaizen philosophy. CURRENT SITUATION Background Toyota Motor Corporation (NYSE: TM) is a multinational corporation with headquarters in Japan. They are the world’s most profitable automaker, now having 15% market share in the U.S. (Taylor, 2007) They sold 2.5 million cars and trucks last year alone, causing them to displace Chrysler’s Big Three position in car sales in the U.S. Soon Toyota estimates it will beat out Ford’s sales, and not too distant in the future it will beat GM as well. Toyota has an admirable presence in the U.S., and even Fortune magazine has named Toyota as one of America’s Most Admired Companies—twice in a row. Toyota has returned the gratitude from the U.S. by deciding to enter in to NASCAR racing, and also by introducing the American-targeted Toyota Tundra full-sized pick-up truck. Profitability By no means does Toyota rely solely on the U.S., as their ability to turn...
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...INTRODUCTION Manufacturing has been recognized as the main engine for growth of the economy. Ever changing globalized environment has been posing challenges of competitiveness and survival to all the constituents of the economy. Manufacturers industry have always faced heightened challenges such as rising customer’s demand for better and improved products, erratic demand, and competition in markets. There is no disbelief that the manufacturers are always embracing changes and improvements in their key activities or processes to cope with the ever growing challenges. To be more efficient is the only way to stay and earn profit in a global market. Industries are giving lot of attention to Lean manufacturing. Several industries are struggling to be world class. Principal adoption of lean manufacturing is still found to be complex. Lean Manufacturing is a set of techniques, which have developed gradually over a long period and are based on various minor to major breakthroughs that help in reducing cost and hence increase productivity. Lean is a philosophy of manufacturing that incorporates a collection of principles, tools and techniques into the business processes to optimize time, productivity, HR, and assets, while improving the quality level of products and services to their customers. LEAN MANUFACTURING Lean manufacturing is defined as to produce same and more than the mass production using less effort, lesser space, without any new inventory, better quality and lesser defects...
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... Core concepts of quality, The masters of quality(W Edwards Deming, Joseph M Juran, Philiph B Crosby, Kaoru Ishikawa, Ginichi Taguchi, Shigeo shingo) Evolution of quality, The Total Quality Management Excellence Model, Strategic Quality Management, Lecture, Numerical Exercises on cost of quality, TPM 1. Basterfield H Dale and others, Total Quality Management, Pearson Education/PHI, Inc. 2006. 2. K.Shridhar Bhat Total Quality Management (Himalaya publishing house 2005). 3. Poornima M Charantimath, Total Quality Management, Pearson Education, 2003. MODULE 2 Continuous process improvement: Concepts of Kaizen, Kaizen vs. Innovation, Kaizen Strategy, House of Quality, Quality Function deployment, Quality Circles. Brain storming, Value analysis, Poka Yoke, Bench marking. Lecture, Case study on Kaizen 1. Imai Masaki, Kaizen, The key to Japan’s Competitive Success, McGraw-Hill, Inc., International Edition, 1991. 2. 3. Heizer and Nathan, Cases in Total Quality Management Manufacturing and services, Thomson South-western, 2004....
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