Seshat Consulting Group: Kaizen

Seshat consulting group
Syria:+963 944 763715 UAE:+971 508244318 Egypt ( Main office) : +2-01000778933
SESHAT Consulting Group
KAIZEN
Egypt( Main office): rafik@seshatconsulting.com
Syria: info.syria@seshatconsulting.com
UAE: info.emirates@seshatconsulting.com
www.seshatconsulting.com

Kaizen
What is Kaizen? - In simple terms Kaizen is Japanese for a change for better, which results in continuous improvement. Kaizen ideology can be traced back to the 1980s; Kaizen was first adopted in the West with the influx of TOYOTA Japanese car manufacturers brought a wave of new thinking. Kaizen uses the Japanese logic of bringing improvements internally from within the workplace; this goes against the European ethics of using external sources such as consultants to improve processes. Kaizen is a process of stepwise improvement. It focuses on implementing continuous change over time. Kaizen is a popular word in industry, worldwide, to claim practicing innovative management methods. KAIZEN represents Work culture. KAIZEN represents for gradual improvement in day today work practices. KAIZEN encompasses methodology of PDCA cycle. PDCA cycle means PlanDo- Check and Act. The focus is on Employee Involvement. Kaizen concentrates at improving the process rather than at achieving certain results. Every company employee is encouraged to come up with ideas. Successful Kaizen help build a Lean culture and measurably improve company performance. Kaizen method consists of 5 basic founding elements: 1. 2. 3. 4. 5. Teamwork Personal Discipline Improved Morale Quality Circles Suggestions for Improvement

Kaizen Benefits
Problems are identified at source, and resolved. Small improvements which are realized can add up to major benefits for the business Improvements, which lead to changes in the business quality, cost and delivery of products, mean a greater level of customer satisfaction, and business growth. By involving employees in looking at their environment to bring about change, results in improved morale as people begin to find work easier and more enjoyable.
Kaizen in Textile and Garment Industry

Quality may be defined as the level of acceptance of a goods or services. For the textile and apparel industry, product quality is calculated in terms of quality and standard of fibers, yarns, fabric construction, color fastness, designs and the final finished garments. In Egypt, different garments factory follow different quality control and management systems especially different inspection systems for garment inspection. Quality control in terms of garment manufacturing, pre-sales and posts sales service, delivery, pricing, etc.. are essential for any garment manufacturer, trader or exporter. Certain quality related problems, should never be over looked. The consumers want to get high quality products in low price. The products should reach the consumers with right quality depends on the cost. Quality management is the aspect of the overall management function that determines and implements the quality policy. Quality assurance covers all the process within a company that contributes to the production of quality products. The inspection is carried out by representatives of the current production and the result record on control chart. The aim of garment inspection is to visually inspect articles at random from a delivery in order to verify their general conformity and appearance with instruction/description and/or sample received.

What would SESHAT provides

SESHAT 's training program gives participants the knowledge required to implement kaizen and tools to improve continuously in future. SESHAT 's methodology is based on action learning model and real time project implementation. The SESHAT 's Kaizen Program give participants basics of Kaizen, its techniques and how to implement it in the organization for effective results. Who should attend Kaizen Courses 1) Any individual who wish to learn Kaizen and its tools. 2) Any individual who wish to implement real time project.
Kaizen Training In a glance ..

Value vs. Non-Value
Egypt( Main office): rafik@seshatconsulting.com Syria: info.syria@seshatconsulting.com UAE: info.emirates@seshatconsulting.com

Everything that we do should be questioned for value. When considering an activity or process, ask yourselves: Would your downstream users perceive this as adding value? If our downstream users (customers) knew we were providing the activity or process: Would they be willing to pay for it? Would it meet their expectations? Definition of a Value Stream: All ESSENTIAL actions (people, info, materials) to bring a product or service through the main process steps from beginning to end. Definition of a Value Stream Map: A diagram that shows all steps, whether they are Value Added, Non-Value Added, or Non-Value Added but Required.
The 8 Forms of Waste

1. Mistakes/Reworks 2. Excess Inventory (includes material, time and information) 3. Transporting (Unnecessary Transport of Materials) 4. Motion (Unnecessary Movement of People) 5. Waiting 6. Processing (Excess Process Steps) 7. Overproducing (Services/Goods do not meet the Needs of the Customer) 8. Failure to Utilize the Time and/or Staff Talents
Examples of Tools
6S: Sort, Simplify, Sweep, Standardize, Sustain, Safety TPM (Total Productive Maintenance): keep equipment in perfect working order to reduce breakdowns Value Stream Map Spaghetti Charts: shows people and material flow in an area to determine travel times and rerouting The 5 Whys: used to identify the true (root) cause of a problem Process Mapping: shows each step in a process Takt Time: how fast you need to produce to meet downstream demand Work Balancing/Leveling: each process step takes about the same amount of time and workload is evenly distributed among staff all to meet downstream demand Poka-Yoke: proofing a process to eliminate errors and incorporate quality control DFEU (Design for Ease of Use): design process to eliminate waste, be as simple as possible, and easy to use One Need Flow: Reduce batch size to as small as possible Flow Cells: Placing people/equipment close together to allow uninterrupted flow Kanban: signal to indicate delivery of a specific supply to a specific process location Visual Workplace: reflects status of Work Area and tracking of performance measures
Lean Element & Rules

Elements: Value Stream Flow: no process moves faster than the slowest step Pull: continuous flow of info/materials through a process to meet downstream demand Perfection: eliminate waste, continue to improve processbecoming the BEST at everything we do Elements: Standard Work: everyone does the process exactly the same way every time Limit Material/Information Travel Limit People Hand/Feet Travel Lean Education for All
Program outline
Pre-Event

Identify process/system for improvement and primary stakeholders. Complete Specific Problem Statement (Project Charter/Case for Change) Get approval from Sponsor. Identify Team Leader and Facilitator (Lean Champion). Identify Team members - include those who actually perform work in the area. Schedule pre-planning meeting with Team Introduce Kaizen, 8 Forms of Waste, standard work, value vs. non-value, value stream mapping. Finish Project Charter/Case for Change: Business Case, Specific Goal Statement, Scope of Project Collect process data/statistics. Schedule Kaizen Event date. Notify all staff of Event (open-door policy). Gather supplies the day before the Event.
Day 1
Review of Lean Elements, Rules, Tools Review Problem Statement, Goals and supporting documentation. Warm-up Activities (The Customer, 5 Whys). Review Team Rules. Develop Current State Map (take photos). Identify Value Added (VA), Non-Value Added (NVA), and Non-Value Added but Required activities (NVAR). Calculate VA, NVA, NVAR, and Total Cycle Time.
Day 2
Identify Waste in Current State Map. Create Future State Map (take photos). Develop Standard Work and Single Piece Flow. Develop Visual Workplace.
Day 3
Determine if all Goals have been met. Identify outcomes (performance measures). Complete Kaizen Implementation Plan/Assignments (limit to two weeks). Finalize PowerPoint.

Identify Presenter Roles for Management Presentation. Closing: Lessons Learned, Future Items to Address. Take Team photo.
Post-Event
Present to Management. Post Event details and photos on a bulletin board or a common area. Celebrate and communicate your success with others. Complete all assignments from Kaizen Implementation Plan. Train staff!
Duration: 5 Days Location: Sonesta Hotel; 3 el Tayaran street, Nasr City, Cairo, Egypt. Dates: 18th and 19th of January 2012 Time: 9:00 AM 5:00 PM. Price per Person: 1300 EGP Payment Terms: 100 % prior to session start date. For Inquiry and Registration: Please send an e-mail to rafik@seshatconsulting.com or contact us at +2-01000778933

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Seshat consulting group

Syria:+963 944 763715 UAE:+971 508244318 Egypt ( Main office) : +2-01000778933