Lean six sigma process improvement tools and techniques by donna summers chapter 13

Kaizen and Error Proofing Chapter 13... Kaizen and Error Proofing • ‘Strive to improve work procedures and think through solutions to simplify them’... Kaizen and Error Proofing • Kaize

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Donna C. Summers

Kaizen and Error Proofing

Chapter 13

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Donna C. Summers

• ‘Strive to improve work procedures and

think through solutions to simplify them’

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Donna C. Summers

• 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’

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Donna C. Summers

• 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.

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Donna C. Summers

• Kaizen

– Guiding words

• Combine

• Simplify

• Eliminate

– Kaizen seeks to standardize work processes

while eliminating waste.

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Donna C. Summers

• 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.

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Donna C. Summers

• 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

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Donna C. Summers

• Poka-yoke = foolproof mechanism

– Poka-yoke or error proofing is used to

counteract human variation or error (Shigeo

Shingo)

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Donna C. Summers

• 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

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Donna C. Summers

• 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

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