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Approach to KAIZEN

Approach to KAIZEN. Quality Assurance Department Komatsu Ltd. February 2005. Kaizen( Improvement ). Stabilized era of economical field allowed just to follow the Job Description. Job shall be variable depending on environmental surroundings. Today. Future.

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Approach to KAIZEN

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  1. Approach to KAIZEN Quality Assurance Department Komatsu Ltd. February 2005

  2. Kaizen( Improvement ) Stabilized era of economical field allowed just to follow the Job Description Job shall be variable depending on environmental surroundings Today Future Work = Job Description + Improvement Surroundings always change. Egoistic customers Present High quality and low price

  3. Have you satisfied ordinal countermeasurement?

  4. Power necessary for improvement

  5. Approach to the Hypothesis and Test

  6. Hypothesis and Testing Time study of work resulted such Histogram shown left. What kind of information can you get? Graph says. 〔Information〕 ・ Average 60 min, Max. 90 min, Min. 30 min ・ Wide range of Working time 〔Hypothesis〕 The job may be completed within 30 min. 〔Result〕 〔Testing］ Take memo of the process done within 30 min. Then try it. Working time could be reduced 30 min.

  7. How to proceed KAIZEN • Step 1: Decide Theme • Step 2: Study Theme • Step 3: Set Target • Step 4: Analyze Factors • Step 5: Countermeasure • Step 6: Break through complex • Step 7: Implementation-5W1H • Step 8: Check actual impact

  8. Step 1: Decide Theme

  9. Step 2: Study ThemeMake clear characteristics

  10. Latent Problems ・Meeting ・E-Mail System

  11. Read a Graph C:Periodical shift A: Sharp shift Aha･･･ B: Slow shift

  12. Pareto Diagram • What we could find. • Malfunction at 1st Floor • Mr. A and B made mistake • Copy density • →Check machine at first floor • especially density adjustment

  13. Histogram

  14. CheckCorrelation using Scatter Diagram Problem B: IT Problem C: Printing Communication Utilization of IT: B Problem A: Too many copy Cost Number of copy :A Number of copy :A

  15. Scatter Diagram Correlation factor -1＜r＜0 Negative correlation r=0 No correlation 0＜r＜+1 Positive correlation Effect for diet Effect for diet Effect for diet Kcal of meal Time in reading Exercise

  16. Then pile up factors Number of copy Facility Too many copy paper Correlation Latent Problems Utilization of PC Printing cost Job process Mind Frequent meeting No paper Environment Number of copy Number of copy

  17. Step 3: Set Target Pareto Diagram Histogram 3 Factors Upper limit • What • By when • How much Lower limit Target: More than 90% Target: Eliminate A and B Average to be smaller Average 77% Target: A shall be less than B Target: CS must be more than 90% Customer’s satisfaction

  18. Step 4: Factor AnalysisCause and Effect Diagram To segment asking WHY and WHY Major small Problem Backbone

  19. Step 5: Countermeasure

  20. Step 6: Break through a fixed idea Enlarge area A Shrink area D

  21. Step 7: ImplementationCounter measurements have to be carried out. • Issue an Action Plan describing 5W1H clearly. • Consider PDPC (Process Decision Program Chart) for implementation.

  22. Example of PDPC

  23. Step 8: Check actual impact

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