...Unit 3 Individual Project – Principals of Process Improvement American Intercontinental University Introduction Innovative continuous improvement have become a critical element for organizations that want to continue to grow in a market that is ever changing and competitive for market shares. As a result of this growing need to do things faster, cheaper and more efficiently various methods of continuous improvement have been developed and incorporated into business environments to evaluate and streamlining processes to do more with less. In this assignment my evaluation of improvement process will be in the areas of quality and safety within a production environment. I will identify and compare established well defined process improvement methods, as well as, provide a series of recommendations that, if implemented, will assist with the fictional organizational goal that has been requested by the department managers at this company. Principals of Lean Manufacturing Lean Manufacturing is defined as a production practice that uses less and fewer resources than traditional manufacturing. The primary objective of implementation of lean processes is to eliminate any element of the process that does not add value and striving for perfection with zero defects and zero inventories. (Lynch, 2005) There are various principals to lean manufacturing that can be applied to any area of an organization to realize the process improvement in the assignment below I will...
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...Have the Continuous Improvement (Cl) efforts at Absa Bank’s Horizon Medium Business Banking unit, in the Gauteng West region successfully addressed the key concepts of Continuous Improvement as set out by Trollip, 2008? By Sinqobile Khobotho Ndlovu {20625261} Submitted in partial fulfillment of the requirements for the degree of Masters in Business Administration At the Nelson Mandela Metropolitan University (NMMU) Business School Research Supervisor: Mr. Bux Heather November 2008 Page 1 of 112 Declaration “I, Sinqobile K Ndlovu, declare that: • This work has not been previously accepted in substance for any degree and is not being concurrently submitted in candidature for any degree. • This dissertation is being submitted in partial fulfillment of the requirements for the degree of Masters in Business Administration. • The dissertation is the result of my independent work/investigation, except where otherwise stated. Other sources are acknowledged by referencing and a reference list is attached. • I hereby give consent for my dissertation, if accepted, to be available for photocopying and for loan, and for the title and summary to be made available to outside organizations.” Signed: …………………. Date: 20 December 2008 Page 2 of 112 Abstract Success in today’s highly competitive financial sector requires an organization to have a sustainable competitive advantage that would distinguish it from the rest. Products...
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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 from...
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...White paper KAIZEN COSTING AND VALUE ANALYSIS content THIS DOCUMENT.......................................................................................................... 1 CUT THE PRICE OF YOUR COMPONENTS WHILE TURNING A PROFIT.......................... 1 A closer look at the complication............................................................................ 2 IN THE FOOTSTEPS OF QUALITY ASSURANCE TECHNOLOGY. .................................... 2 . KAIZEN COSTING: A DEFINITION............................................................................. 4 . A standard system:................................................................................................. 4 A Kaizen system:. ................................................................................................... 4 . KAIZEN ESTIMATES IN PRACTICE................................................................................. 5 CHOICE OF PERSPECTIVE............................................................................................. 6 VALUE ANALYSIS IS NECESSARY................................................................................... 8 DEVELOPING METHODS FOR COST RATIONALIZATION.............................................. 8 WHAT ARE THE BENEFITS OF KAIZEN COSTING?........................................................... 9 KAIZEN COSTING AND VALUE ANALYSIS KAIZEN COSTING AND VALUE ANALYSIS THIS DOCUMENT This White Paper describes the costing...
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...Philippines Technological University of the Philippines Ayala Boulevard, Ermita Manila IM – 10: Production Management CHAPTER VIII. Production Process Improvement For Product Innovation Submitted by: Tugade, Erwin Benedict P. Liang, Dongping (Jessie) BAM – IM – 4LE Submitted to: Noel B. Hernandez, Ph. D. Topics to be discussed 1. Production Process. 2. Characteristics of A Production Process. 3. Importance of Continuous Process improvement. 4. Innovation Drivers of Change. 5. Reverse Engineering. 6. Kaizen. Objectives * To be able to know what is Product Innovation. * To identify the reason of Continuous Innovation. * To be able to enumerate different factors Necessitating Change in Process Design * To introduce some new ways of thinking about continuous improvement. * To understand innovation as drivers of change. * To discuss about Reverse Engineering and Kaizen. Introduction To win in manufacturing, not only do you need the ability to innovate, but you must also execute upon that innovation and deliver new product to market before your competitors do. That's true manufacturing agility, and it can't happen if your enterprise is burdened by isolated plant-based execution systems that lack coordination between headquarters, engineering and the shop floor. As Blanchard (2005) believes that innovation is the successful exploitation of new ideas. And companies’ success, for example, means increased...
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...at three casinos with over 4,000 employees; however, during those Kaizen events he was able to pull staff from other hotel areas to ensure sufficient coverage of daily operations. At the new Metropolis property, Mr. Hirsch needed to determine whether to proceed with implementing lean principles and tools with an expertise-based process improvement team or the traditional route with the casino employees learning and implementing processes from the ground up. Mr. Hirsch has several alternatives to consider and weigh to determine the best solution for this stand-alone property, its 600 employees and thousands of customers. He must take into consideration the pros and cons of each of these alternatives and analyze how these decisions will affect not only the processes within the organization, but the employees and customers as well. If he brings in experts to apply lean principles and tools within Harrah’s Metropolis Casino, he would not have to train line employees to analyze and improve processes themselves and would not experience the temporary loss of productivity that traditional lean implementations have. He could save time and money by selecting this approach; however, he would lose the momentum and emergent effects of the employees and activities involved in the Kaizen events. This lack of employee ownership of the new processes and procedures from lean could be a problem if continuous improvement projects are something the organization wants to build itself on. If he selected...
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...Lean Event (Kaizen Blitz) Agenda 1. What is Lean Event 2. Purpose of Lean Event 3. Lean Event Plan 4. Benefits of Lean Event Development of Lean Event (Kaizen Blitz) Kaizen Continuous incremental improvement Blitz To make a great effort to do something that needs to be done • • The origin of Lean Event concepts are pioneered by Toyota Production System. The concepts enabled the Toyota Production System to be the best in the world. Definition of Lean Event 1. Kaizen Activity – which means small step increment or continuous improvement activities 2. Short-term, intensive and focus effort to dramatically to improve the performance of a limited scope process. 3. Process for improving QDC by eliminating wastes 4. Process for learning Lean Manufacturing techniques 5. Technique to simplify existing processes with minimum money and maximum use of the people who daily make them work 6. The beginning of Lean transformation on the production shop floor Purpose of Lean Event 1. Speed of improvements can be realized quickly 2. Team are focused and free from daily operational issues 3. Team are creative and practical ideas are generated. 4. Intensity and urgency overcomes the intellectual resistance to new paradigm or ideas 5. Results generated are significant, clear and quick which will translate into enthusiasm and satisfaction. 6. Human development are enhanced as lean knowledge are being applied and transfer by relevant parties 7. Enhanced Learning by Doing Lean Event Principles...
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...Lean Manufacturing Assignment-2 By: Yuganshu Jain (2012ABPS695P) Background of The Company: Mahindra & Mahindra Group is one of the prestigious automobile manufacturing organizations in India. With the dual objective of industrial and agriculture growth, Mahindra & Mahindra was established in 1970. Mahindra & Mahindra, is India’s first large-scale project based company with a totally indigenous design, know-how and technology. Mahindra & Mahindra is a leading manufacturing organization manufacturing tractors, harvesting combines, fork lifters etc. Till 1998, the organization did not give much attention to the maintenance work. The machines were being checked and repaired only after the breakdown. But with the industrialization, it became necessary to adopt new concepts to survive in the market. The organization decided to adopt “Total Productive Maintenance (TPM) for its survival. Problems Faced Due To Maintenance The importance of maintenance functions has increased due to its role in keeping and improving the availability, product quantity, safety requirements, as maintenance costs constitute an important part of the operating budget of manufacturing firms. The Company operated at less than full capacity, with low productivity, and the cost of producing products are high. Almost 25-30% of total production cost is attributed to maintenance activities in the factory. Hence the quality of maintenance significantly affects business profitability. There was a lot of variation...
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...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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...development Starting from preparation of development contract until equipment is ready to be introduced to the business. It is also a stage where the factory trials take place. Cost of product design, prototyping, and market testing costs. 3) Production All the manufacturing costs related to producing the products such as direct material, labor, overhead and administrative costs will be incurred. 4) Distribution and customer (or logistical) support This stage is where product are sent to customers and ready to be used. All marketing, selling and distribution costs are incurred at this stage. As for logical support cost, it involves delivery and transportation costs, warehousing costs, dismantling cost and costs for abandonment of the project and some equipment might need to be disposed of or recycled. All expenditure for resources that are likely to arise must be addressed. Future costs are also taken into consideration and will be discounted to the present value. LCC includes all the upstream costs and downstream costs. Upstream costs...
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...regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE 2. REPORT TYPE 3. DATES COVERED 2004 4. TITLE AND SUBTITLE N/A 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER The Lean Enterprise-A Management Philosophy at Lockheed Martin 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Office of the Under Secretary of Defense for Acquisition Technology & Logistics 9820 Belvoir Road Fort Belvoir, VA 22060-5565 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER 10. SPONSOR/MONITOR’S ACRONYM(S) 11. SPONSOR/MONITOR’S REPORT NUMBER(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release, distribution unlimited 13. SUPPLEMENTARY NOTES 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: a. REPORT b. ABSTRACT c. THIS PAGE 17. LIMITATION OF ABSTRACT 18. NUMBER OF PAGES 19a. NAME OF...
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...KAIZEN COSTING THE PERFORMANCE OF THE ORGANIZATIONS TABLE OF CONTENTS Page Table Of Contents 1 1.1 Introduction 2 1.2 The Concept Of Kaizen Costing 2 1.3 Kaizen And Management 4 1.4 Kaizen -The Three Pillars 5 1.4.1 Housekeeping 5 1.4.2 Waste (Muda ) Elimination 7 1.4.3 Standardization 10 1.6 Kaizen And Total Quality Management (Tqm) 13 1.7 Kaizen And Suggestion Systems 14 1.8 Goals Of Kaizen Vs. Quality, Cost And Delivery 15 1.9 Common Disconnects/Roadblocks In Kaizen Implementation 16 1.10 Advantages Of Kaizen Costing 17 1.11 Disadvantages Of Kaizen Costing 18 1.12 Conclusion 19 References 19 1.1 Introduction Kaizen means improvement, continuous improvement involving everyone in the organization from top management, to managers then to supervisors, and to workers. In Japan, the concept of Kaizen is so deeply engrained in the minds of both managers and workers that they often do not even realize they are thinking Kaizen as a customer-driven strategy for improvement. Kaizen is a Japanese philosophy for process improvement that can be traced to the meaning of the Japanese words ‘Kai’ and ‘Zen’, which translate roughly into ‘to break apart and investigate’ and ‘to improve upon the existing situation’. It is using common sense and is both a rigorous, scientific method using statistical quality control and an adaptive framework of organizational values and beliefs that keeps workers and management focused on...
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...The Benefits of Implementing Kaizen and Measuring its Success Abstract This paper serves as a literature review of kaizen. Points of interest include its origins, how it is different from innovation, its benefits, and its implementation. Difficulties of implementing kaizen are addressed briefly. Standardization and sustainability may just be the most difficult elements of the kaizen process. However, they are perhaps the most important aspects of kaizen, yet they are sometimes overlooked. This can lead to failed kaizen attempts even as severe as reverting back to the old, supposedly improved upon standards. A particular research program looked at inputs to kaizen events and how they affect the outcome of the events. It emphasizes the importance of recognizing failure and using that feedback to improve the effectiveness of the kaizen event initiative. This research program is also referenced in this paper. Introduction After World War II, the United States felt it could benefit from assisting the Japanese economy. The United States sent those who contributed to American businesses during the war to act as advisors to Japanese businesses, one of whom was Dr. W. Edwards Deming. Deming’s ideas that made the Japanese increasingly competitive came to be known as kaizen (Maurer 9-10). What is Kaizen? Dr. Deming’s ideas that became known as kaizen included reduction of waste, respect for workers, and service to the customer (Maurer 9). Kaizen is a Japanese term that is...
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...Toyota Operations Management maintenance of the production of goods or services 1. Introduction Operations management is the maintenance of the production of goods or services that a company is developing for sale. The management team is charged with the task of ensuring a profitable and safe production system, and also ensuring that resources are allocated and used in an efficient manner, minimizing waste in labour and material resources. In order to meet these goals, the management team thus has to attempt to find the best operations strategy available for their particular situation and product. The biggest challenge for any organization and its operations is to try to maximize productions by cutting down on waste, Finding the right balance between getting the production up to the required standard by using the resources available to the optimal level. There are many strategies that can be used by an operations manager depending on the needs of production, and in the first section we will examine some existing operation management strategies, and in the second section we will examine the effectiveness of these strategies, and how well they fit in with the goals of the target organization, Toyota. 2. Operations Managers Role The Role of an operations manager is of utmost importance as any operations manager who can effectively utilize an organizations resources to efficient effect by producing outputs of a standard & sustainable quality, contributes to the organizations...
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...Team B will identify a quality management system for process or organizational improvement as well as summarize the requirements of the choose system. Team B will explain how the chosen quality management system will benefit the organization as well as define the variation identified in the as is flowchart. Finally, Team B will detail the implementation plan for the chosen quality improvement process and provide examples of the quality tools that be used for indentifying and reducing process variability. Quality Management System for Improvement Team B will recommend that Hartman Industries, LLC introduce the Kaizen approach as the quality management system. “Kaizen is the name given by the Japanese to the concept of continual incremental improvement” (Goetsch & Davis, 2010, p. 494). This sums up what Team B hopes to give to Hartman Industries. In the Kaizen approach, “the improvement aspect of Kaizan refers to people, processes, and products” (Goetsch & Davis, 2010, p. 494). This...
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