JAPANESE AND OTHER PRODUCTIVITY

TECHNIQUES IN MANUFACTURING
Kaizen, JIT, Kanban and Poka- Yoke
Submitted to- Prof. Ajit Kurvey

INDEX
Introduction

Management Kaizen
JIT
Kanban
Poka-yoke

Bibliography

Improvement Function

INTRODUCTION
Japanese manufacturing techniques generally approach
productivity with the goal of reducing unnecessary
expenses, waste and time, while increasing production
and efficiency.
Many of the modern Japanese manufacturing techniques
were developed after World War II and peaked in the
1980s.
Large companies such as Toyota are credited with
pioneering many of the manufacturing techniques used
by Japanese companies and these techniques have spread
to non-Japanese companies as well, due to their
effectiveness

IMPROVEMENT FUNCTION - KAIZEN

Kaizen: The Key to Japan's Competitive Success
This method became famous by the book of Masaaki
Imai which means KAI Change & ZEN Good i.e
improvement.
It means works continuously towards revising the
current standards, once they have been mastered, and
establishing higher ones.
Improvement can be broken down between innovation
and Kaizen.
Kaizen signifies small improvements as a result of
coordinated continuous efforts by all employees.

IMPROVEMENT FUNCTION KAIZEN(CONTD...)

By improving standardized activities and processes,
kaizen aims to eliminate waste as in lean
manufacturing( Toyota Production System )
Kaizen was first implemented in several Japanese
businesses after World War II, influenced in part by
American business and quality management teachers
who visited the country
It is also a process that, when done correctly,
humanizes the workplace, eliminates overly hard work,
and teaches people how to perform experiments on
their work using the scientific method and how to learn
to spot and eliminate waste in business processes.

KEY PRACTICES

Customer Orientation

Determine the perceptions, needs, and wants of target markets

Satisfy them through the design, communication, pricing

Quality Control Circle (QCC)

Discipline in the work place

Co-operative Labor Manager Relations .
TQM

Come together to discuss with the management issues related to either quality
control or improvement in production methods.
Voluntarily meet on a regular basis to identify, analyze and solve their problems.

Functions on the premise that the quality of the products and

processes is the responsibility of everyone who is involved with
the creation or consumption of the products or services offered by
the organization.

Quality Improvement

It is a formal approach to the analysis of performance and

systematic efforts to improve it. There are numerous models used.
Some commonly discussed include: PDSA , Six Sigma , CQI,
TQM

Automation and Robotics

Autonomation

It is automation with a human touch .

If there is a problem the machine can not resolve , the

production is stopped and the human workers look into the
matter and apply countermeasures so that such things do not
happen again .
Kanban

Just-in-time
Zero defects

It tries to bring defects in production to zero .

Total Productive Maintenance

the machine operator is thoroughly trained to perform much of

the simple maintenance and fault-finding.

KAIZEN AT TOYOTA
There are two kinds of kaizen activities at Toyota:
kaizen made by the supervisory staff and engineers as
their functions,
that made by workers through the quality circles and
suggestion system.
Cost of each of the parts and a standard time for their
production.
A maintenance team
An assembly line is divided into about ten segments per
function
A large conveyer installed on the ground level permit
workers to operate
Tasks to carry heavy parts also disappeared by installing
automatic or semi-automatic equipment .

FEATURES OF KAIZEN

Improvements are based on many small changes

Small improvements are less likely to require major

capital investment.

The ideas come from the talents of the existing

workforce

Continuous improvement in individual performance

FEATURES OF KAIZEN( CONTD...)

It helps encourage workers, thereby improving

worker motivation

Kaizen is a daily process, the purpose of which

goes beyond simple productivity improvement.

humanizes the workplace, eliminates overly hard

work ("muri"),

Teaches people how to perform experiments on

their work using the scientific method and how to
learn to spot and eliminate waste in business
processes.

COMPANIES IMPLEMENTING KAIZEN

Jit is a strategy used in inventory management.

With JIT strategy companies aim to decrease waste and inventory
costs by receiving goods only when they are needed to produce.
JIT inventory mgmt thus increases efficiency and is used by companies
that prefer to keep low inventory levels.
In order for JIT to work corrctly the company must be able to predict
demand for the product and how much inventory will be needed at what
stages
It has also been described as an approach with the objective of producing
the right part in the right place at the right time.

KEY ELEMENTS OF JIT.

Reduce or eliminate setup times.
Reduce lot sizes.
Reduce lead times.
Preventive maintenence.
Flexible workforce.

ADVANTAGES OF JIT.
Lower stock holding means a reduction in storage space which
saves rent and insurance costs
As stock is only obtained when it is needed,
working capital is tied up in stock
There is less likelihood of stock perishing ,becoming obsolete or
out of date.
Avoids the build-up of unsold finished product that can occur
with sudden changes in demand
Less time is spent on checking and re-working the product
of others as the emphasis is on getting the work right first time

DISADVANTAGES OF JIT.
There

is little room for mistakes as minimal stock is kept for

re-working faulty product
Production is very reliant on suppliers and if stock is
not delivered on time, the whole production schedule can be delayed.
There is no spare finished product available to meet unexpected orders,
because all product is made to meet actual orders
however, JIT is a very responsive method of production

IMPROVEMENT FUNCTION KANBAN

Kanban (literally signboard or billboard) is a
scheduling system for lean and just-in-time (JIT)
production. According to its creator, Taiichi Ohno,
kanban is one means through which JIT is achieved
It is a inventory scheduling system that helps
determine what to produce, when to produce it, and
how much to produce
The need to maintain a high rate of improvement
led Toyota to devise the kanban system. Kanban
became an effective tool to support the running of
the production system as a whole.

IMPROVEMENT FUNCTION
KANBAN(CONTD...)

Basic Principles:Start with what you do now

Agree to pursue incremental, evolutionary change
Respect the current process, roles, responsibilities &
titles
Leadership at all levels

IMPROVEMENT FUNCTION
KANBAN(CONTD...)

Kanban cards

Three bin System

Electronic systems

POKA YOKE
Japanese

for mistake-proofing

Poka - inadvertent mistake

Yoke prevent

Developed
Either

in the 1960s

prevents a mistake from

being made or makes the mistake
obvious at a glance


The cause of defects lie in worker errors, and defects are a
result of neglecting those errors mistakes will not turn
into defects if worker errors are discovered and eliminated
beforehand - Shingo

THREE TYPES OF INSPECTION

Judgment

inspection
Informative inspection
Source inspection
Often

Poka Yoke devices

ensure the proper operating
conditions exist prior to actual
production

POKAYOKE DEVICE CATEGORIES

Prevention

device - make
errors impossible

Detection

device - Make
errors visible to the operator

CHARACTERISTICS OF GOOD POKA YOKE DEVICES

they

are simple and cheap

they are part of the process
they are placed close to
where the mistakes occur