Basic Idea of Japanese Style "KAIZEN"

The way of "KAIZEN"
using Ppeople's Power

The way of "Innovation"
using Capital & Outside Power

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Technical Design Corporation
7-1, Narihira 5-Chome, Sumida-Ku, Tokyo (130-0002), Japan
TEL 03-3624-9428  FAX 03-3624-9435
E-mail : K.Katakura@techdsn.com
Copyright 2008

"KAIZEN" is
Step by Step Improvement using People's Power
without big investment.

Overview of "KAIZEN" phases

 Basic Idea of 5S

Overview

SQC Approach for Problem Solving.

Continuous Inprovement using Control Chart

SQC Approach

Using Control Chart

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SampleSize
for AV Chart for R Chart
n1/2 A A2 d2 1/d2 D1 D2 D3 D4
2 1.414 2.121 1.880 1.128 0.8862 3.686 3.267
3 1.732 1.732 1.023 1.693 0.5908 4.358 2.575
4 2.000 1.500 0.729 2.059 0.4857 4.698 2.282
5 2.236 1.324 0.577 2.326 0.4299 4.918 2.115
6 2.449 1.225 0.483 2.534 0.3946 5.078 2.004
7 2.646 1.134 0.419 2.704 0.3698 0.205 5.203 0.076 1.924
8 2.939 1.061 0.373 2.847 0.3512 0.387 5.307 0.136 1.864
9 3.000 1.000 0.337 2.970 0.3367 0.546 5.394 0.184 1.916
10 3.162 0.949 0.308 3.078 0.3249 0.687 5.469 0.223 1.777

Parameter Table for AV-R Chart Design

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Control Chart (Example)

Aims of "ControlChart"

1. Autonomous Quality Control.
2. Assuring Product Quality at the time.
3. Immediate action taking at the time
  for both the product and the process.
4. Develop/keep operative's motivation..
5. Improve the process condition
  using step by step and PDCA cycle.


 Our believings

  Operatives have potential to improve.
    1. Every operative knows every detail of the situation in work-shop,
      and every operative knows what's wrong, what's real problem and what's better.
    2. Every operative wants to be developped and to have satisfaction on his/her work.
    3. Every operative wants to improve his/her work place and his/her work.

  Operatives will perform to improve as a team.
    1. Operatives will be motivated through two way communications with bottom-up policy.
    2. Operatives will be developped through OJT (on the job training).
    3. Operatives will be working with care and thinking through 5S program.

    4. Operatives will perform together as a team through 5S program.
    5. SQC tools will accelerate improvement activities and optimization of the process.
    6. Continuous improvement will be developped with TQM/TQC concept.

  Quality First

    1. Quality stabilization makes process stabilization.
   
2. Less wastage & more productivity will be realized following quality stabilization.
    3. Quality level will make market demand more.

Basic Concept of JP style TQM
All member's perticipation from bottom to top.
Picking up opinions and suggestions from bottom.
Working together as a team.
Sharing data and information among members.
Talk using quantative data.
Looking at real or truth at the time at the place.
Following PDCA cycle.
Development skilllevel and knowlege.

Improvement points through 5S program.

1.. Keeping clean and tidy to ensure the work/process condition.
2. Standardization and putting everything in to order.
3. Eliminating 3M.
     Muri (Over capacity, over load and difficulties)
     Muda (Waste of time, space, materials, movements and so on)
     Mura (Un-stable, poor planning, missmuching, un-balance and so on)
4. Changing to increase the efficiency.
     from difficult access to easy access.
     from long distance to short distance.
     from slow movement to quick movement.
     from complicate to simple.

Key of KAIZEN

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