Global Corporate Overview

KAIZEN Institute ®

Consulting Group (KICG)

The #1 Specialist in:

World Class Performance…
Operational Excellence…
Continuous Improvement Kaizen Lean !

KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute Version 1.1
 Who are we: Kaizen Institute Consulting Group (KICG)
Introduction

Founded KAIZEN Institute in

Zug, Switzerland in 1985:
• 1 Global Coordination Office;
• 29 Local Kaizen Offices;
• 400+ Specialists.

Taiichi
Ohno Wrote the books KAIZEN
1912 – 1990 and GEMBA KAIZEN
Dalian, China

Traveled with Shoichiro

Toyoda and Taiichi Ohno

Worked at the Japan

Productivity Center

Masaaki Imai was born

in Tokyo, Japan

1930 1955 1962 1976 1980 1985 2012

2 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 Who are we: Kaizen Institute Consulting Group (KICG)
Kaizen Institute and Gemba Research Join Forces

Sweden
Germany Russia
Poland
Canada Belgium Czech
Switzerland Slovakia
France Hungary
Spain Romania Japan
USA
Austria
Portugal Italy China

UAE
Mexico India
Singapure

Kenya Malaysia
Uganda
Brazil

Mauritius

Australia
Global Operations
Headquarters in Switzerland New Zealand
Business Units
25 Years of Worldwide Kaizen Merged
Lean Transformation 1st of January 2011
Experience (founded in 1985).

3 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

The Meaning of KAIZEN
Our Mission

KAI Change

ZEN for the better

K A I Z E N = CI - Continual Improvement (Lean)

Everybody!
Everyday!
Everywhere! ... Kaizen Culture!

4 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 Our Service Portfolio
A Kaizen Lean Strategy in All Types of Business Processes

Discrete Assembly Project Management

Storage & Transport

Discrete Production Administration & Services

Process Industry

5 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 Our Service Portfolio
Some of our Customers

Semicontuctor

Heavyindustry

Automotive

Pharmaceutical

Service

Processindustry

Foodindustry

Consumption

Machine building

6 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The Meaning of KAIZEN
What is a successful Kaizen Lean Strategy?

Improvement across all … at higher rates and for

critical Organizational longer periods than
Objectives... competitors ...
CULTURE

CUSTOMER
… Orchestrated by
SATISFACTION management ...
TRANSFORMATION

… leading to growth
PRODUCTIVITY and improvement in
Corporate Performance…
+ … and driven by
WORKING CAPITAL GROWTH a Physical and
Behavioral Change …

EBITDA
CAPEX

7 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The Meaning of Kaizen
The Market Championship

My Company My Customer Old Championship

Customer
Value Winning Through
Company Utility Capacity Leadership:
Value
Price
= An Expansion Strategy…
Demand
Cost
Bigger Than = A “More of the Same” Culture !
Offer

My Company My Customer Today´s

Customer
Value
Utility
Championship
Winning Through
Utility / Cost Leadership:
Company
Value
= A Kaizen Lean Strategy…
Price
Market
= A “Continuous Improvement”
Culture !
Cost Determines
Price

8 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The Meaning of Kaizen
Creating Strategic Value with Engaged People

Define Long Term Value To Our Customers and To Our Company

Challenge Kaizen Teams Set Targets and Organize Kaizen Teamwork

Go to Gemba To Change Processes and People

Behaviors

Awareness of Customer Non-Satisfaction

Search For
and Process Waste

Make KAIZEN = Improve Customer Utility

Change for the Better and Eliminate Waste
GEMBA = Real Work place (where value is added)

9 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The Meaning of Kaizen
The Kaizen Flag: Involving People at All Levels

s of 3
e Ty
Typ en s K a p es
3 aiz ge
K len Te ize of
al am n
C h s
Support Kaizen
Motivation Improvement

Design VALUE
into GEMBA INNOVATION Management
Project Kaizen
Process Improvement

Create VALUE
in GEMBA
IMPROVEMENT Supervisors
- P.D.C.A.
Daily Kaizen
Teams Improvement

Maintain VALUE STANDARDIZATION Employees

In GEMBA
- S.D.C.A.

S.D.C.A. = Standardize, Do, Check, Act;

P.D.C.A. = Plan, Do, Check Act.
10 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute
 The Meaning of Kaizen
Lean Results at a Faster Speed

Improvement
SUPPORT KAIZEN
Develop Strategy

Kaizen Way
Customer PROJECT KAIZEN
Develop Processes
Satisfaction

Sales
DAILY KAIZEN
Develop Teams

Profits

Company
Culture

Innovation only –
Traditional Way
Time
11 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute
 The KMS – Kaizen® Management System
Model for WCP - World Class Performance, Operational Excellence and CI

S Financial C
u Success u
p s
p t
l People Kaizen® Lean Customer W.C.P. o
W.C.P.
i Development Transformation Value m
e e
r Process r
s Improvement s

TFM TPM TQM TSM IDM

Total Total Total Total Innovation &
Flow Productive Quality Service Development
Management Maintenance Management Management Management

KCM – KAIZEN® Change Management

Build up a solid basis with:

Eliminate: MUDA-Losses Eliminate: MUDA-Waste
KAIZEN® Foundations

12 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
Model for WCP - World Class Performance, Operational Excellence and CI

S Financial C
u Success u
p s
p Objectives:
People
Clear & Measurable
Kaizen Lean Customer ®
t
l W.C.P. W.C.P. o
i Development Transformation Value m
e e
r Process r
s Improvement s

TFM TPM TQM TSM IDM

Total Total Total Total Innovation &
Flow
Management
Training Methods: Effective
Productive
Maintenance
Quality
Management
Service
Management
Development
Management

Frequent
KCM – KAIZEN®Practice: Daily
Change Management

Build up a solid basis with:

StrongKAIZEN
Eliminate: MUDA-Losses
Motivation:
Foundations Beliefs
®
Eliminate: MUDA-Waste

13 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
Total Flow Management (Effective Flow Improvement System)

II. Production Flow III. Internal Logistics Flow IV. External Logistics TFM History
Flow

TFM Introduction
5. Low Cost 5. Production Pull 5. Logistics Pull
Automation Planning Planning

TFM Overview
4. Smed 4. Leveling 4. Deliver Flows

3. Standard 3. Synchronization
(KB/JJ) 3. Source Flows
Work

2. Border 2. Mizusumashi 2. Milk Run

of Line

1. Line and 1. Storage and

Layout Design 1. Supermarkets Warehouse Design

I. Basic Reliability

V. Supply Chain Design (SCD)

14 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
TPM: Total Productive Maintenance

Introduction 12 Steps Road Map JIPM Project Practice

Coach Motivation Audit Practice

Promotion Visual
Figures
Management

One Point
Lesson

15 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
TQM: Total Quality Management

Level 0 Level 1 Level 2 Level 3 Level 4

Defects reach Defects don’t Reduce defects Isolate defects Zero defects
the client reach the client

Operatio Operatio
n n
Process Process Process JK
Inspection
Operatio
n
Operatio JK
n
DEFECTS DEFECTS Operatio
DEFECTS Inspection n
Inspection Inspection

Defects OK OK OK OK
Complains SDCA
Re-work
Problem Solving

Kaizen Tools
Poka-Yoke
Improvements Auto-Quality Matrix
JK Jidoka 6σ Projects
Defects Design 6σ

16 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
TSM: Total Service Management

Process Flow Process Quality Process Management

Low Cost
Auto-quality Resources Planning
Automation

Office
Kobetsu Kaizen Work Planning
Standard Work

Archive and Stock

Workflow Design 3C
Management

Daily Kaizen Natural Teams

Team Job
5S Standardization Job Relations
Organization Instruction

Value Chain Analysis & Design

Process Landscape Process Mapping Muda Hunting

17 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
IDM: Innovation & Development Management

3. Continuous 4. Lean Project 6. Preventive

5. Flow Improvement
Innovation Management Management
Business Model Portfolio & Capacity Industrialization
Canvas Q.F.D.
Management Strategy

Blue Ocean Strategy Obeya Monitoring Supply Chain Design Design for Cost

Organization
Pull Project Planning Lean Line Design D.O.E. & Taguchi
Structure Design
Product & Service
Project A3´s Process LT Reduction F.M.E.A.´s
Ideation
Business Case Concurrent
Stage-Gate Standards Performance Review
Creation Engineering

2. Development Teams

Team Foundations Work Planning Standard Work Problem Solving

1. Development Mapping

Project Portfolio
Muda Hunting Exercises Project Mapping
(Landscape)

0. Application Areas
5.
5. New
New Business
Business
1.
1. New
New Product
Product 3.
3. New
New Equipment
Equipment 7.
7. Event
Event Organization
Organization
Model
Model // Process
Process

2.
2. New
New Plant
Plant 4.
4. Maintenance
Maintenance Overhaul
Overhaul 6.
6. Construction
Construction 8.
8. Software
Software Development
Development

18 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute

 The KMS – Kaizen® Management System
Model for WCP - World Class Performance, Operational Excellence and CI

S Financial C
u Success u
p s
p t
l People Kaizen® Lean Customer W.C.P. o
W.C.P.
i Development Transformation Value m
e e
r Process r
s Improvement s

TFM TPM TQM TSM IDM

Total Total Total Total Innovation &
Flow Productive Quality Service Development
Management Maintenance Management Management Management

KCM – KAIZEN® Change Management

Build up a solid basis with:

Eliminate: MUDA-Losses Eliminate: MUDA-Waste
KAIZEN® Foundations

19 KAIZEN and GEMBAKAIZEN are trademarks of the KAIZEN Institute