Your Questions About Kaizen

Linda asks…

wat r t companies tat use kaizen and Z theory?

John answers:

You need to learn to do web searches. Countless companies all over the world.
Http://www.nytimes.com/2007/02/08/business/08scene.html
http://www.vitalentusa.com/learn/kaizen_list.php
http://www.graphicproducts.com/tutorials/kaizen/kaizen-benefits.php
http://www.1000ventures.com/business_guide/mgmt_kaizen_main.html
http://en.wikipedia.org/wiki/Kaizen

Ken asks…

Opinions on Kaizen kettlebells?

Has anyone used or bought them? If so how are they? Good quality? I ask because they look great and are way more cheaper than kettlebells from elsewhere but I am wondering just what the quality is because of the price. Thanks

John answers:

Yup

Lizzie asks…

How expensive are the commercial eletric rates in DFW?

Everything on google is an add for a quote! I need to know how much KWH my work is charged for a Kaizen project.

John answers:

Commercial rates average about 8 cents a kwh. U can get lower if you have higher usage.

Joseph asks…

Kaizen 7 wastes?

Can anyone tell me what the 7 wastes in the Kaizen philosphy are? Cant remember them all and text books are at work.

Thanks

John answers:

The 7 Wastes of Production
Taiichi Ohno defined the 7 types of waste that describe all activity that adds cost but not value. In a Lean Enterprise these 7 types of “Muda” are the target of an endless pursuit of waste elimination. Learning to see “Muda” all around you is the key to starting out on your journey of transforming your organization into a Lean Enterprise.

The 7 Wastes – “Muda”
Definition
Examples
Causes
Countermeasures

Over-|production
Producing more than the customer needs right now
Producing product to stock based on sales forecasts

Producing more to avoid set-ups

Batch process resulting in extra output
Forecasting

Long set-ups

“Just in case” for breakdowns
Pull system scheduling

Heijunka – level loading

Set-up reduction

TPM

Trans-
portation
Movement of product that does not add value
Moving parts in and out of storage

Moving material from one workstation to another
Batch production

Push production

Storage

Functional layout
Flow lines

Pull system

Value Stream organizations

Kanban

Motion
Movement of people that does not add value
Searching for parts, tools, prints, etc.

Sorting through materials

Reaching for tools

Lifting boxes of parts
Workplace disorganization

Missing items

Poor workstation design

Unsafe work area
5S

Point of Use Storage

Water Spider

One-piece flow

Workstation design

Waiting
Idle time created when material, information, people, or equipment is not ready

Waiting for parts

Waiting for prints

Waiting for inspection

Waiting for machines

Waiting for information

Waiting for machine repair
Push production

Work imbalance

Centralized inspection

Order entry delays

Lack of priority

Lack of communication
Downstream pull

Takt time production

In-process gauging

Jidoka

Office Kaizen

TPM

Processing
Effort that adds no value from the customer’s viewpoint
Multiple cleaning of parts

Paperwork

Over-tight tolerances

Awkward tool or part design
Delay between processing

Push system

Customer voice not understood

Designs “thrown over the wall”
Flow lines

One-piece pull

Office Kaizen

3P

Lean Design

Inventory
More materials, parts, or products on hand than the customer needs right now
Raw materials

Work in process

Finished goods

Consumable supplies

Purchased components
Supplier lead-times

Lack of flow

Long set-ups

Long lead-times

Paperwork in process

Lack of ordering procedure
External kanban

Supplier development

One-piece flow lines

Set-up reduction

Internal kanban

Defects
Work that contains errors, rework, mistakes or lacks something necessary
Scrap

Rework

Defects

Correction

Field failure

Variation

Missing parts
Process failure

Mis-loaded part

Batch process

Inspect-in quality

Incapable machines
GembaSigma

Pokayoke

One-piece pull

Built-in quality

3P

Jidoka

Susan asks…

what is synonyms of “kaizen”. Please help me ?

WHAT IS ONE WORD SUBSTITUTION OF “KAIZEN“.

John answers:

Never heard of it in the English language! If you’re talking about the Japanese word though,
?? ?????? (n,vs) betterment; improvement; incremental and continuous improvement;

Or…
Main Entry: kaizen
Part of Speech: noun
Definition: Japanese for continuous and incremental improvement, a business philosophy about working practices and efficiency; improvement in productivity or performance
Etymology: Japanese `change for the better’

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