KAIZEN vs KAIKAKU thinking

1. A Picture of the thinking required for KAIKAKU
Contrast and Compare KAIZEN thinking to KAIKAKU thinking
VS
Kaizen Thinking Kaikaku Thinking
Incremental Change <> Tortoise Velocity Step Change <> Rocket Velocity
A Picture of the thinking required for KAIKAKU
Contrast and Compare KAIZEN thinking to KAIKAKU thinking
PDCA SDCA from Honorable Imai Masaaki
PDCA and SDCA Systematic KAIZEN Improvement Pathway Created by: Todd McCann
(from Gemba KAIZEN Masaaki
PDCA and SDCA Step Change KAIKAKU Pathway Created by: Todd McCann
(from Gemba KAIZEN Masaaki
Imai)
Imai)
The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009
Rev: 3
The Natural Progression of Improvement by applying Systematic Thinking Date: 3-15-2009
Rev: 3
(Plan – Do – Check – Act with Standardize – Do – Check – Act) (Plan – Do – Check – Act with Standardize – Do – Check – Act)
Measure
Measure
Unit 1 July 08 MWt 8 hr avg.
Unit 1 July 08 MWt 8 hr avg.
LSL USL 3458
A P
LSL
Target
Process Data
3456.5
*
LSL USL 3458
Within
Overall
LSL
Target
Process Data
3456.5
*
Within
Overall
Potential (Within) C apability
Act Plan
P
Potential (Within) Capability USL 3457.5
KAIZEN
USL 3457.5
A Cp 1.09
Sample Mean 3456.77 Cp 1.09
C PL 0.59
Sample Mean 3456.77
Sample N 693 C PL 0.59
StDev(Within) 0.152393 C PU 1.59 Sample N 693
StDev(O verall) 0.354484 C pk 0.59
StDev (Within) 0.152393 C PU 1.59
C Cpk 1.09
StDev (O v erall) 0.354484 C pk 0.59
Ov erall Capability
C C pk 1.09
Act
C
Pp 0.47
Plan O v erall C apability
D
PPL 0.26
PPU 0.68
Ppk 0.26 Pp 0.47
C pm *
PPL 0.26
PPU 0.68
Ppk 0.26
3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4
C pm *
Observ ed Performance
PPM < LSL 225108.23
PPM > USL
PPM Total
1443.00
226551.23
Exp. Within Performance
PPM < LSL 37235.72
PPM > USL
PPM Total
0.88
37236.60
Exp. O verall Performance
PPM < LSL 221596.02
PPM > USL 19978.92
PPM Total 241574.93 C D 3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4
Check Do
Check Do
O bserv ed Performance
PPM < LSL
PPM > USL
225108.23
1443.00
Exp. Within Performance
PPM < LSL
PPM > USL
37235.72
0.88
Exp. O v erall Performance
PPM < LSL
PPM > USL
221596.02
19978.92
Measure PPM Total 226551.23 PPM Total 37236.60 PPM Total 241574.93
KAIZEN Improvements
Unit 1 July 08 MWt 8 hr avg.
A P
KAIKAKU Improvement
LSL USL 3458
Process Data Within
LSL 3456.5 Overall
Target *
Potential (Within) Capability
Act
USL 3457.5
Sample Mean 3456.77 Cp
C PL
1.09
0.59
Plan
KAIZEN
Sample N 693
StDev(Within) 0.152393 C PU 1.59
StDev(O verall) 0.354484 C pk 0.59
C Cpk 1.09
Ov erall Capability
Pp 0.47
P
PPL 0.26
PPU 0.68
3456.0 3456.4 3456.8 3457.2 3457.6 3458.0 3458.4
Ppk
C pm
0.26
*
C D A
Observ ed Performance Exp. Within Performance Exp. O verall Performance
Check Do KAIZEN
PPM < LSL 225108.23 PPM < LSL 37235.72 PPM < LSL 221596.02
Act
PPM > USL 1443.00 PPM > USL 0.88 PPM > USL 19978.92
PPM Total 226551.23 PPM Total 37236.60 PPM Total 241574.93
Plan
VS
Measure A S
Act Standardize
C D
P S
Unit 1 July 08 MWt 8 hr avg.
LSL
Process Data
3456.5
LSL USL 3458
Within
Overall
A Check Do A
Target
USL
Sample Mean
Sample N
*
3457.5
3456.77
693
Potential (Within) Capability
Cp
C PL
1.09
0.59
Act Plan C D
StDev(Within) 0.152393
StDev(O verall) 0.354484
C PU 1.59
C pk
C Cpk 1.09
0.59
Ov erall Capability
Pp
PPL
0.47
0.26