Faculty of Mechanical Engineering

Assessment Cover Sheet

Student Name Mohammad Khairi bin Mohammad Date Received

Student ID 2015238536

Assessment Title Individual Assignment I

Programmes EM220 Mark Awarded

Lecturer Amirul Bin Abd Rashid (Ir. Dr.)

Due Date 4 April 2019

Date Submitted 4 April 2019

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 Table of Content
1. Introduction ........................................................................................................................ 1

2. Research result ................................................................................................................... 2

A. First case study: Applying Lean Principles and Kaizen Rapid Improvement Events
in Public Health Practice ........................................................................................................ 2

I. Problem statement ....................................................................................................... 2

II. Approach used ......................................................................................................... 2

III. The impact of the kaizen .......................................................................................... 3

B. Second case study: Total Productive Maintenance (TPM) Implementation in A

Machine Shop ........................................................................................................................ 4

I. Problem statement ....................................................................................................... 4

II. Approach used ......................................................................................................... 4

III. The impact of kaizen................................................................................................ 7

3. Conclusion ......................................................................................................................... 7

4. Reference ........................................................................................................................... 8

5. Appendices ......................................................................................................................... 9

A. Individual Assignment Rubric .......................................................................................... 9

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 List of figures
Figure 1: Tool board as a Poka Yoke device[4] ........................................................................ 5

Figure 2: Fish bone diagram[4].................................................................................................. 5

Figure 3: Current layout[4] ........................................................................................................ 6

Figure 4: Proposed layout[4] ..................................................................................................... 6

List of tables
Table 1: Intangible and tangible results ..................................................................................... 3

Table 2: Analysis from fish bone diagram[4] ............................................................................ 6

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 1. Introduction

In this modern era, manufacturing has evolved considerably since the advent of
industrial revolution. In current global and competitive age, it is very important for
organization to have manufacturing practice which is lean, efficient, cost-effective and
flexible. World Class Manufacturing is a collection of concepts, which set standard for
production and manufacturing for another organization to follow. Japanese manufacturing is
credited with pioneer in concept of world-class manufacturing[1].

By mentioning Japanese manufacturing, it can be related to the philosophy of kaizen

which introduced by Toyota's Taichi Ohno which means "continuous improvement"[2]. It
aims to improve all aspects of a company, including productivity, quality and employee
satisfaction. The participation in kaizen should be extended to all employees, in cross-
functional teams.

For this assignment, the students are needed to identify and investigate the examples
of kaizen that was successfully carried out to improve any of the area including quality,
safety, culture, processes, leadership, technology, organization, productivity and others. The
students must explain clearly about the problem statement, the approach used, and the impact
of the kaizen based on the examples.

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 2. Research result

Based on my identification and investigation for the examples of kaizen, I managed to

find 2 case study which are “Applying Lean Principles and Kaizen Rapid Improvement
Events in Public Health Practice” and “Total Productive Maintenance (TPM) Implementation
in A Machine Shop”. Those case studies are suitable example to explain briefly in term of
problem statement, approach used and the impact of kaizen. Hence, below are the details of
explanation regarding the case studies.

A. First case study: Applying Lean Principles and Kaizen Rapid Improvement
Events in Public Health Practice

I. Problem statement

This case study describes a local home health and hospice agency’s effort to
implement Lean principles and Kaizen methodology as a rapid improvement approach
to quality improvement. The agency created a cross-functional team, followed Lean
Kaizen methodology, and made significant improvements in scheduling time for
home health nurses that resulted in reduced operational costs, improved working
conditions, and multiple organizational efficiencies.

II. Approach used

In this case study, the approach used is the Kaizen Event or rapid
improvement event that one of the most successful lean tools, which typically require
4 to 5 consecutive days of improvement work focused on empowering frontline staff
and utilizing their knowledge to create more effective and efficient processes[3]. They
are using kaizen methodology as their approach for major problem-solving activities
and changed their culture.

They held 4-day Kaizen event by utilizing the Plan-Do-Study-Act cycle to

perform small tests of change before making larger-scale changes. The process began
with a brief lean overview training session followed by a team process review walk
called a “Gemba walk” which the team are able observes directly the actual process
to gain a common understanding of how the process functions and observe wasteful
activities. The team then created a value stream map of the scheduling process and

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listed the wasteful items on their map. The team identified 3 areas to focus
improvements:

1. The quality of the information coming into the agency’s intake staff

2. Issues and delays faced by the staff in the field who service patients

3. Reducing time required making daily assignments so nursing staff could see
patients sooner

Also, on the last day, the team began preparing for a future Kaizen event,
including a “5S” which are sort, set-in-order, shine, standardize, and sustain
approach, and overall workplace organization for their home health medical supply
room and storage area. Over the next 90 days, the team met regularly to finalize
pending items from the Kaizen[3].

After the success of its first project, the company began incorporating Lean on
a regular basis and Kaizen events are now regularly used for problem solving. The
company has adapted the Kaizen approach to meet its needs by setting aside a half
day for project definition, a Gemba walk, debriefing waste, mapping the process,
brainstorming improvement ideas, and creating a list of Plan-Do-Study-Acts to test. In
the weeks that follow, they work on testing ideas and small changes. The team meets
again for another half day to review outcomes and revisit discussions on adjustments
or next steps.

III. The impact of the kaizen

After implementing lean principles and Kaizen methodology, it produces

intangible and tangible results which can refer on table 1.

Table 1: Intangible and tangible results

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B. Second case study: Total Productive Maintenance (TPM) Implementation in
A Machine Shop
I. Problem statement

Quality and Maintenance of manufacturing systems are closely related

functions of any organization. Over a period of time, two concepts have emerged
which are Total Productive Maintenance (TPM) and Total Quality Management
(TQM) along with other concepts such as kaizen to achieve World Class
Manufacturing system. In this case study, implementing Total Productive
Maintenance is shared and investigated for a company manufacturing automotive
component for improving the utilization of CNC machines[4]. One of the concepts,
kaizen is implemented in the machine shop having CNC turning centres of different
capacity. The aim implementing kaizen at the CNC company is to improve in
processes and productivity.

II. Approach used

There are 3 approaches implemented which are:

 Poka Yoke Device

It is Japanese term in English which means mistake proofing or error
prevention. There are two types of Poka Yoke device which are warning or
prevention type and detecting type[4]. As in the factory, the tool board is
made in-house as a Poka Yoke device as shown in Figure 1. It is warning
type mistake proofing devices which will visually warn operator or helper
if they are trying to put spanners at the wrong place.

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 Figure 1: Tool board as a Poka Yoke device[4]

 Fish bone diagram and corrective action

One of the problems occur in the factory is that the leakage of the
coolant. To identify the reasons of coolant leakage, fish bone diagram is
prepared (figure 2) and corrective action constructed (table 2) to solve
related to the identified problems.

Figure 2: Fish bone diagram[4]

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 Table 2: Analysis from fish bone diagram[4]

 Propose New layout

The company need to propose new layout design to minimize the
handling of parts in order to improve the productivity since the
management has decided to purchase two new CNCs to meet the
production requirement. So, it is necessary to redesign the layout of CNC
shop floor. Hence below are present layout and proposed layout.

Figure 3: Current layout[4]

Figure 4: Proposed layout[4]

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 III. The impact of kaizen

The goal of the any TPM program is to improve productivity and quality along
with increased employee morale and job satisfaction. Earlier preventive maintenance
was considered as non-value adding process, but now it is essential requirement for
longer life cycle of machines in an industry. TPM is an innovative approach to
maintenance that optimizes equipment effectiveness, eliminates breakdowns, and
promotes autonomous operator maintenance through day-to-day activities involving
the total workforce. One of the concepts from the TPM is kaizen which give an impact
towards the Overall Equipment Effectiveness that improved from 63% to 79%
indicating the improvement in productivity and improvement in quality of product[4].

3. Conclusion

In a nutshell, upon reflection regarding those 2 case studies, it proves that

implementing kaizen helps improve quality, processes, and its productivity.

As we know that World Class Manufacturing (WCM) is a mindset based on a

continuous improvement approach which has its foundations in the Total Productive
Maintenance (TPM) a maintenance process developed in Japan for improving productivity by
making processes more reliable & less wasteful[5]. WCM came up with the innovation and
also kaizen which will give a competitive advantage for the company for the long-term period
due to its gradual and continuous improvement.

Regarding the first case study, it describes a local home health and hospice agency’s
effort to implement Lean principles and Kaizen methodology, which resulted in reduced
operational costs, improved working conditions, and multiple organizational efficiencies.
This shows that the kaizen methodology gave a big impact towards the company in a long-
term period in most of the aspects. This case study suggests that Lean improvement and
kaizen methods may be one effective approach for public health agencies to optimize their
resources and improve in the area of quality.

Then for the second case study, it focuses on the improvement area of processes,
quality and productivity by implementing one of the pillars of TPM, kaizen in a phased
manner is leading to continuous improvement of the company. There is also the analysis of
the data before and after implementation of the pillar. Overall equipment effectiveness (OEE)
is taken as a measure of success of the pillars of the TPM’s implementation.

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 4. Reference

[1] “World Class Manufacturing - Meaning and its Principles.” [Online]. Available:
https://www.managementstudyguide.com/world-class-manufacturing.htm. [Accessed:
04-Apr-2019].

[2] “Kaizen: Continuous Improvement.” [Online]. Available: https://world-class-

manufacturing.com/Kaizen/improvements.html. [Accessed: 04-Apr-2019].

[3] G. Smith, A. Poteat-Godwin, L. M. Harrison, and G. D. Randolph, “Applying lean

principles and kaizen rapid improvement events in public health practice,” J. Public
Heal. Manag. Pract., vol. 18, no. 1, pp. 52–54, 2012.

[4] R. Singh, A. M. Gohil, D. B. Shah, and S. Desai, “Total productive maintenance

(TPM) implementation in a machine shop: A case study,” Procedia Eng., vol. 51, no.
NUiCONE 2012, pp. 592–599, 2013.

[5] “It is our ‘ Continuous Improvement System ’ Founded in TPM What is World Class
Manufacturing ? WCM is a mindset based on a continuous.”

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 5. Appendices
A. Individual Assignment Rubric

Scale 1 2 3 4 5

Self
Criteria Poor Acceptable Excellent Mark
Review

Topic is poorly Topic is fairly Topic is well

Introduction
introduced. Lack of introduced. introduced. Clearly 4
(CO1)
understanding on Moderately explain on the topics.
the topic. understand on the
topic.
Well and thorough
Content Research Fairly general research in the
Result Topic is poorly research on the WCM concept and
discussed. Lack/ 40
WCM concept. its applications.
absent of
(CO2) Some supporting Effective
supporting
evidence. evidence is supporting
provided. evidence is
provided.
Conclusion
Unclear conclusion Topic is fairly Topic is well 40
(CO2) of the topic. concluded. concluded.

 Writing is
 Writing is well
disorganized,  Writing is found
Format organized and
unfocused to the to be in
covered relevant to
main theme and accordance with the course
Organizati (CO1) disconnected. course 3
requirements and
on  Not following the requirements topics for
required format and have some discussions.
of presentation. focus on
 Each sub-topic is
discernible clear and well
theme and structured.
supporting
details.
 Writing lacks
 Excellent writing
clear sentences
Writing and paragraphs.  Writing skills skills in the use of
are somehow words and prefect
Language  Deficiencies in 3
clear and grammar.
(CO1) good
paragraphs  Sources of
grammatically skill
are well reference are well
witting.
structured. cited with complete
Less explanation of
grammar tables and figures
mistakes
 Able to make use
of all relevant and
 Adequate available
use of resources
 Inadequate use resources effectively
of resources
 Receptive to  Receptive to new
 Not receptive to some new ideas ideas, critics,
Lifelong new ideas and and partially able suggestions and
Utilization Learning unable to utilize to act able to act
them accordingly 10
of autonomously
 Lack of interest  Show interest  Show strong
resource (CO4) interest and
and curiosity in and curiosity
s acquiring new curiosity in
in acquiring
knowledge new acquiring new
 Not many knowledge knowledge and
resources and expanding it to
explored expanding it new horizon
 Inadequate or no through new through
citation of resources resource
resources utilization utilization.

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  Adequately  Many
cite all resources
references explored
 Sources of
reference are
well cited with
complete
explanation
of tables and figures

Total 100

Note: This case study will be given an overall grade of 10% marks (CO1 – 1%, CO2 – 8%, CO4 – 1%)
of the course.

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