Kaizen means “improvement.”.It is a continuous improvement process that involves everyone, from managers to workers.
Its aim is to enhance production processes through small but effective changes.

Module Content

• The Concept of Kaizen and Its Historical Development
• Objectives and Benefits of Kaizen
• The Relationship Between Kaizen and the PDCA Cycle
• The Concept of the Suggestion System
• Methods for Establishing an Effective Suggestion System
• The Relationship Between Kaizen and the Suggestion System
• The 8D Concept, Phases of the 8D Method, and Implementation Stages
• Use of the 8D Method in Kaizen Activities
• Problem-Solving Tools (Fishbone Diagram, Pareto Analysis, 5 Whys Analysis)

Module Learning Outcomes

• Will be able to understand the place and importance of Kaizen in businesses and identify application points.
• Will be able to identify chronic problems.
• Will be able to ensure problems are solved before they escalate.
• Will be able to prevent recurrence of errors by identifying root causes of problems and implementing permanent solutions.
• Will be able to ensure processes are carried out consistently, stably, and successfully, maintaining high-quality outputs.
• Will be able to properly design a suggestion system.
• Will be able to solve a problem using Kaizen.
• Will be able to apply the 8D method for problem-solving.
• Will be able to apply Fishbone analysis, Pareto analysis, and 5 Whys analysis for a process.

Who Should Attend?

Operation/production managers, engineering managers, quality managers, senior supervisors, engineers, and technicians—essentially, operational decision-makers.

Jidoka and Poka Yoke

Jidoka is translated as automation and is based on the principle of detecting problems. It is one of the most important lean principles that can help achieve true perfection.

Poka Yoke is a lean manufacturing method that prevents operators from making mistakes (poka) during manual tasks. Its purpose is to prevent, correct, or detect human errors before they occur. The term was coined by Shigeo Shingo.

Module Content:

• The Concept of Jidoka and Its Historical Development
• Objectives and Principles of Jidoka
• Jidoka Implementation Principles
• The Concept of Andon and Examples
• Proper Andon Design
• The Concept of Poka Yoke (Definitions of Errors and Defects, Types of Errors, Types of Defects)
• Benefits of Poka Yoke
• Poka Yoke Criteria
• Poka Yoke Implementation Techniques and Examples

Module Learning Outcomes for Participants:

At the end of the training, participants will be able to:

• Understand the place and importance of Jidoka in businesses.
• Comprehend the differences between automation and autonomation.
• Conduct a Poka Yoke study for a process.
• Anticipate cost reductions resulting from a decrease in workforce size.
• Improve their organization’s ability to adapt to changes in demand.
• Prevent defective parts from proceeding to the next process by separating them at the source.
• Enable error prevention without relying on human intervention through Poka Yoke practices.
• Reduce costs caused by errors such as defective workmanship and scrap.
• Identify Andon requirements for a process and implement proper Andon placement.