EFFECTIVE MANUFACTURING TOOLS

KAIZEN CONTINUOUS IMPROVEMENT

INTRODUCTION
KAIZEN is one of the famous Japanese philosophy on continual improvement. Kaizen means improvement, which is ongoing and involve everyone.

OBJECTIVES
To train the participants in continuous improvement and proposal system of Kaizen so that they can contribute in the company’s continuous improvement program.

OUTLINES
SECTION 1: THE CONCEPT OF KAIZEN
• Terms & Definition
• Introduction to Kaizen & Key Elements of Kaizen
• Gemba Kaizen
• Kaizen and the Suggestion System
• Process-oriented Management vs Result-oriented Management
• Group Exercise

SECTION 2: KAIZEN VS INNOVATION
• Difference Between Maintenance, KAIZEN & Innovation
• KAIZEN vs Innovation
• KAIZEN and Measurement
• the Roles of each Hierarchy KAIZEN Involvement
• Exercise

SECTION 3: TOTAL QUALITY CONTROL
• Japanese Vs Western Approaches
• CWQC (Company Wide Quality Control)
• TQC Deals with the Quality of People
• Definition of Quality Control
• The Japanese TQC Approaches
• Characteristics of TQC

SECTION 4: THE PRACTICE
• 3 Main Segments for KAIZEN Implementation
• Management-oriented KAIZEN
• Group-oriented KAIZEN
• Individual-oriented KAIZEN
• Group Exercise
• Sample of 5M for Fish Bone Diagram
• 7 QC Tools
• Sample of Action Plan

SECTION 5 : GETTING READY
• 4 Stages of Implementation ( Training, Planning, Implementing & Auditing )
• Some Tips to get Started
• The Wet Blanket List

Who Should Attend?
Top Management, Managers, Executives, Engineers, Supervisors, Technicians etc.

Duration
One Day.

8D CORRECTIVE ACTION

COURSE OBJECTIVES

• To understand the 8 disciplines of corrective action method in problem solving

• How to use team behaviors throughout the 8D process

• How to describe a problem using the 5W and 2H method

• How to identify and verify root cause of a problem

• How to implement solutions and corrective actions

• To understand the 8D documentation requirements

• Importance of preventive action

 

OUTLINES

What is 8D Corrective Action?

8D Corrective Action Steps

8D Corrective Action Flow Chart

APPLICATION of 8D

1D USE TEAM APPROACH

• include people involved with the problem and affected by it may need experts or specialists to help

2D DESCRIBE THE PROBLEM

• Who, What, When, Where, Why, How many, How often

• State the problem in terms at this customer

3D CONTAINMENT AND SHORT TERM CORRECTIVE ACTION

• Root cause is not important at this point

• Take defensive actions to protect the customer from problem

4D DEFINE AND VERIFY THE ROOT CAUSE (S)

• Fishbone analysis or other techniques should be used

• Verify the root cause – make it reproducible

5D IMPLEMENT PERMANENT CORRECTION ACTION

• Take actions to permanently address root cause (s)

6D VERIFY EFFECTIVENESS OF PERMANENT CORRECTIVE ACTION

• Use quantitative methods to determine if fix was effective

7D PREVENT RECURRENCE

• Improve the system to prevent problem from recurring

• Spread lessons learned to other similar processes or products

8D CONGRATULATE THE TEAM

WHO SHOULD ATTEND?

Top Management, Executives, Supervisors etc.

DURATION

One Day.