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Training Film on One Piece Flow


Learning is not a choice, it is a winning habit. We believe in Continuous Learning Process that evolves out of Daily Gemba Observation and Continuous Reflection. By the way, Gemba means the Real Workplace, where all the action happens.

When electrons flow, it creates Electricity, wind carries energy but hidden in its flow, water can turn turbines when its flow is converted. It makes us smile when we see the queue flowing everywhere. Flow by itself is a powerful philosophy of maximizing opportunities for growth and justified higher returns. Flow of money keeps us in good books. Flow brings health, harmony and happiness all around.

This training film is an attempt to bring out the concept of One Piece Flow in total understanding with practical reference to the implementation of the Flow. This film One Piece flow manufacturing aims to train Lean and Kaizen enthusiasts on its objectives in daily production. The movie has lots of information in it on the benefits of implementing "One Piece Flow". Real examples have been taken from ZF Steering & Gear, Toyota Kirloskar etc. The films comprises examples on concepts like Heijunka, Mizusumashi, Continuous flow, videos from the shop-floor, animations to describe concepts of flow, waste etc

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5"S" for Higher Productivity and Workplace Excellence


5S is the most popular Japanese Management technique that has its root of origin in all cultures. It talks about the Workplace Organization and bringing systematic discipline in daily work that we perform. 5S is also considered an excellent tool for Housekeeping or Material Storage.

5S is the starting point of transformation towards creating Workplace Excellence. 5S in Japanese denotes: Seiri, Seiton, Seiso, Seiketsu and Shitsuke which literally mean Sorting, Systematic Arrangement, Spic and Span, Standardisation and Self Discipline respectively. Implementation of 5S will result in a clutter free environment, clean and organised workplace which boosts energy levels and helps in reiterating the process of becoming a World Class Organisation.

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Training Film on War on 8 Waste


Lean manufacturing or lean production, often simply "lean", is a systematic method for the elimination of waste ("Muda") within a manufacturing system. Lean also takes into account waste created through overburden ("Muri") and waste created through unevenness in workloads ("Mura").

Waste is "anything other than the minimum amount of equipment, materials, parts, space, and workers time, which are absolutely essential to add value to the product."" Thus, by the elimination of wastes, we can reduce activities that do not add value to the customer and do not contribute to the profits of an organization!Moreover, when the wastes are reduced, we find more time and resources to focus on the value-added activities which are important to the customer and which do contribute to profits!

This Training film explains the concept of “waste”, illustrates waste in several real-world examples, and provides insights into how to identify and effectively reduce or eliminate waste.

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Poka yoke literally means Mistake Proofing; it is about preventing the creation of defects. Usually it is a simple and inexpensive device or modification to the product itself to prevent there from being any possibility of defects being made

Poka Yoke is a method that uses sensors or other devices for catching errors that may pass by operators or assemblers.Poka-yoke affects two key elements of Zero Defect Quality viz Identifying the defect immediately (Point of Origin Inspection) and Quick Feedback for Corrective Action.

Achieving Zero Defect Quality is essential to maintaining customer satisfaction & loyalty. Poka-yoke will catch the errors before a defective part is manufactured 100% of the time.

This training film explains the concept of Poka-Yoke followed by the live Gemba examples from various industries and the benefits achieved.

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