How to use Kaizen-Getting continiously better for life

Dear Friends,
Good morning, It's Rupesh here again.
In industry almost everyone is talking about kaizen so what is it exactly, how its helpful.

Today's our topic is Kaizen.

What is mean by kaizen?

Kaizen is a Japanese business philosophy of continuous improvement of working practices, personal efficiency, etc.
I words of it's founder Masaaki Imai, Kaizen is a improvement or ongoing improvement consisting everyone from top management, managers to workers.

         "CHANGE FOR THE BETTER"

       ...by Everybody! Everyday! Everywhere!

Kaizen is based on certain guiding principles:

• Good processes bring good results
• Go see for yourself to grasp the current situation
• Speak with data, manage by facts
• Take action to contain and correct root causes of problems
• Work as a team
• Kaizen is everybody’s business
• And much more!

How is kaizen working :

The kaizen is start with idea or after finding the wastage, then find out non value added activity into that. then check reality base impact also make changes again verify that changes also measure the result. Make the standard. celebrate it &do it again. continue the process of changes.

Procedure is based on PDCA cycle. Plan-Do -Check-Act

3 M in Kaizen:

What is 'Muda'?

any activity in your process that does not add value. MUDA is not creating value for the customer. In short: WASTE
Type I muda: Non-value-added tasks which seam to be essential. Business conditions need to be changed to eliminate this type of waste.
Type II muda: Non-value-added tasks which can be eliminated immediately.

What is 'Mura'?

Any variation leading to unbalanced situations. In short: unevenness, inconsistent, irregular.
Mura exists when workflow is out of balance and workload is inconsistent and not incompliance with the standard.

What is 'Muri'?

Muri Unreasonable, impossible, overdoing and overburdened.

Above Muda,Muri, Mura  are useful to identify the waste, so we can start the kaizen process. 

Kay elements of Kaizen:

• Teamwork

• Personal discipline

• Improved moral

• Quality circle

• suggestion for improvement

Case studies-Practical example of factory

1. Increased productivity(Handling time) by proving vertical trolley for wire bundle bunch.

Problem- In my harness manufacturing industry wire entanglement and terminal damage are more problem.

Previously they are using normal tray for wire so these are more problematic, more time consuming to remove entanglement also customer complains of terminal damage.

Action-

Team meeting for solve the problem
Brain storming on the topic of problem with team mates
Root cause found for the problem
We change the trolleys to vertical direction also provide slots for different wire bunch
put that area into under observation for two weeks
Then measure the result
found very effective in terms of quality also handling time reduce.


Benefits of this Kaizen

• Handling time reduced from 30 sec to up to 18  sec due to avoided of entanglement
• Terminal damage issue almost solve, PPM reduce up to 1 from 5
• Productivity prove
• Customer satisfaction level increased

2 Taping change from manual to ondal  machine taping

• Time save also quality improve

3 Wire length reduced up to 70 MM

in harness industry wire are looped under taping so extra length of wire are routed into the bunch
but due to that material loss also extra time required to route

4  welding machine communization

Previously for welding machine process we are using product base layout so all machine are put separate in the project wise, so machine utilization was not 100 % ,some machine are empty due to less order also manpower are ideal accordingly
we change the location of machine one place so utilization of machine increased, so we save almost 5 welding machine also 3 manpower per day its a huge saving the factory.



 we done lot of improvement through  kaizen that is very helpful to your factory also u can use this for home or in our general life.

Improvement in Personal life by Kaizen

here you can take example of my own.

I was very weak in English, I found this is my problem
then I found route cause that grammar problem, also talking in local language with friends and parents.
Action-
I start reading newspaper also start to watch news
Learn about grammar through books & classes.
also started to talk only in English with other

after 3 months I check my English compare old its very improve also my confidant is also increase.


in this way you can apply the kaizen in our personal life.
I will put daily new post please read that ,helpful to all of you.
thanks friends for reading,