Kaizen and Error Proofing Chapter 13 Lean Six

Kaizen and Error Proofing Chapter 13 Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • ‘Strive to improve work procedures and think through solutions to simplify them’ Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Kaizen is the combination of two Japanese words: – ‘kai’ means ‘little’, ‘ongoing’, and ‘good’. – ‘Zen’ means ‘for the better’ and ‘good’. – Pronounced ‘k-eye-zen’ Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Kaizen improvement efforts are little ongoing good improvements that make things better. • Kaizen events are short, highly focused projects that improve the activities in a work area. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Kaizen – Guiding words • Combine • Simplify • Eliminate – Kaizen seeks to standardize work processes while eliminating waste. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Dr. Deming’s 14 points as a continuous improvement efforts foundation: – Create a constancy of purpose toward improvement of product and service, with the aim to become competitive and to stay in business and to provide jobs. • This first point encourages leadership to constantly improve their products or services through innovation, research, education, and continual improvement in all facets of their company. – Constantly and forever improve the system of production and service. • An organization cannot remain truly competitive unless it strives to continually enhance its business processes that provide the products and services their customers want. – Remove barriers that rob people of their right to pride in workmanship. • Barriers are any aspect of a job that prevents employees from doing their jobs well. By removing them, leadership creates an environment supportive of their employees and the continuous improvement of their day-to-day activities. – Institute training on the job • Continual education and training creates an atmosphere that encourages the discovery of new ideas and methods. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Kaizen activities may take two forms: – flow kaizen • focus on value stream improvement • Flow kaizen events study the value stream associated with providing a product or a service. – process kaizen • focus on the elimination of waste. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Poka-yoke = foolproof mechanism. – Poka-yoke or error proofing is used to counteract human variation or error. (Shigeo Shingo) Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Poka-yoke – Kaizen events often focus on error proofing by developing simple methods of preventing human errors from occurring in a process. – Error proof designs do not hinder worker performance, instead they eliminate the chance for error by putting mechanisms in place that prevent wrong action. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.

Kaizen and Error Proofing • Error Proofing (Poka-yoke) – Error proofing has five principles: • • • Elimination Replacement Facilitation Detection Mitigation – Error proofing seeks to improve a worker’s ability to do their job by improving how they do their work. Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved.