Template PROPOSAL OF IMPLEMENTATION OF KAIZEN CONCEPT IN PRATEEK APPARELS

WINTER
PRESENTED BY: ANOOP SINGH PRASHANT GAURAV RAHUL CHOUDHURY BFT-08

WINTER
Template

KAIZEN
KAI
(To change)

WINTER
Template +
ZEN
(make Good, make Better)

= KAIZEN
(Make it easier by studying it, and making the improvement through elimination of waste)

01

KAIZEN

Masaaki Imai Template the developer of is known as Kaizen.

WINTER

Kaizen is primarily a reactive process where you "check" to see if anything is wrong, then go about fixing it. Kaizen is small incremental changes made for improving productivity and minimizing waste.

01

PRATEEK APPARELS PVT. LTD.

Was incorporated in year 1995. Template Largest Apparel manufacturer for Indian market. Prateek Apparels is the biggest manufacturing house for some of the best brands globally such as Levis,

WINTER

 Allen Solly,  Lee, Wrangler (VF brands), Vanhusen

01

IMPLEMENTING KAIZEN
SCOPE-

WINTER
Template

The company is well furnished with cutting edge technology used in garment industry, such as CAD, optimized production system using assembly line flow, and using automatic machines in manufacturing. ERP modules for better information management 5s and other visual improvements implemented. further improvements could be incorporated with Kaizen.

Kaizen as a low-cost, team-oriented approach that leverages company resources.

01

IMPLEMENTING KAIZEN

The competition in cost and lead times in market Template forces company to undergo lean with Kaizen tool. A long term experience of company in field of manufacturing will ensure better improvements with Kaizen tool, reason behind is presence of highly experienced workforce.

WINTER

The theory of Kaizen costing helps to optimize production cost to minimum, providing an edge in 01 market competition.

KAIZEN -PDCA Template Measures for implementing continuous improvement:

WINTER

01

KAIZEN IMPLEMENTATION
Define

WINTER
Template

Meetings and conversations with management, Formation of an empowered Kaizen team, Conducting training sessions workshop, to explain Kaizen concepts for improvement.

01

KAIZEN IMPLEMENTATION
Prepare- training sessions

WINTER
Template
Variability control and

Explaining principles, concepts and problem solving tools used, eg.- Standardize-Do-Check-Act (SDCA), Plan-DOCheck-Act (PDCA), Concepts as-Quality first, recurrence prevention, 5s,

Principles as -types of wastes and standardize work.

01

KAIZEN IMPLEMENTATION
Explore and analyze

WINTER
Template

then go to the work area to apply Key Concepts and write down improvement ideas (objectives). vote on priority of ideas under each concept, develop an action plan for the Key Concept ideas Analyze the feasibility of action plan.

01

KAIZEN IMPLEMENTATION
Execute and record

WINTER
Template

Execute action plan document improvements, present the project to management, and recognize team accomplishments.

Next one to six months

The team meets weekly to review its implementation progress, identify/overcome barriers, celebrate successes, and document its processes.

01

01 KAIZEN implementation

WINTER
Template

KAIZEN COSTING

Process of Template cost reduction during the manufacturing phase of an existing product.

WINTER

Kaizen costing is the maintenance of present levels for products currently being manufactured via systematic efforts to achieve the desired cost level.

02

KAIZEN COSTING
CONCEPT
Cost Focus Cost Mangagement Focus

WINTER
Template Based on Static
Condition Cost control. Compare actual cost to standard costs to meet standards.

TRADITIONAL

KAIZEN

Based on Dynamic Condition Continuously reduce costs based on cost reduction targets. Compare actual cost to kaizen targets.

Employee Focus

May be viewed as the Viewed as the source cause of unfavorable of continuous variances. improvement.

02

HOW ARE KAIZEN COSTING GOALS MET ?

The continualTemplate reduction of nonand relentless value-added activities and costs, the elimination of waste, and Improvements in manufacturing cycle time all contribute to the effort.

WINTER

03

HOW ARE KAIZEN COSTING GOALS MET ?

In addition, the improvement suggestions and Template kaizen efforts of all employees are taken seriously and implemented when appropriate. The result is a continually more efficient and cost-effective production process.

WINTER

03

HOW ARE KAIZEN COSTING GOALS MET ?

Target Costing:

WINTER
Template
the product must be

Time prior to KC is Target Costing Cost at which manufactured.

Critical tool for management as it seeks to strategically design product ensuring low cost and competitive price.

03

Product Specification

WINTER
Price Targets Profit Targets Cost Targets
Major Product/Process Changes
Does Design Meet Target Costs?

Template

Target Costing

Estimated Life Cycle Cost

Are Life Cycle Costs Acceptable ?

Start Production Minor Product/Process Changes Product Scrapping Kaizen Costing

HOW ARE KAIZEN COSTING GOALS MET ?

Cost Reduction:

WINTER
Template

03

TIMELINE OF KAIZEN IMPLEMENTATION Template

Explore & analyze 1 week

WINTER
Execute & record 3-4 weeks Review Total time 24 weeks 33-34 weeks

Define

Prepare

1 week

4 weeks

LIMITATIONS Template

Requires development of detailed cost data.

WINTER

04

May reduce quality of product due to use of cheap components which may be of inferior quality. Difficult to implement in a large scale process where analyzing the process takes a lot of time.

Benefits using Kaizen Concept 04

Empowering of employees, Template Reduce process variation (quality costs) through improved process documentation, Reduce order lead time and Improve communication, both internal and external

WINTER

Benefits using Kaizen Concept 04

Kaizen teams typically improve all three of the major driversTemplate and delivery) by (quality, cost, eliminating non-value adding tasks and improving process documentation.

WINTER

WINTER
Template
THANK YOU