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Kaizen: Total Quality Management - Spring 2010 - IUG 1

Kaizen refers to continuous improvement involving everyone. It originated from Japanese words meaning "change for the better" and refers to constant, gradual improvement no matter how small. The Kaizen system focuses on total employee involvement, empowerment, listening to employees, promoting low-cost improvements, and emphasizing effort over results. Kaizen techniques involve identifying problems, examining them, finding solutions, developing proposals, and implementing them.

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35 views16 pages

Kaizen: Total Quality Management - Spring 2010 - IUG 1

Kaizen refers to continuous improvement involving everyone. It originated from Japanese words meaning "change for the better" and refers to constant, gradual improvement no matter how small. The Kaizen system focuses on total employee involvement, empowerment, listening to employees, promoting low-cost improvements, and emphasizing effort over results. Kaizen techniques involve identifying problems, examining them, finding solutions, developing proposals, and implementing them.

Uploaded by

Nazmus Saquib
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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KAIZEN

Total Quality Management - Spring 2010 - IUG 1


CONCEPT OF KAIZEN
Imai has brought together various
management theories, philosophies and
tools that have been popular in Japan over
the years, as a single concept, Kaizen.

There are many quality experts, whose


principles formed the basis of the Kaizen
concept.

Kaizen means continuous improvement


involving everybody.

Total Quality Management - Spring


2010 - IUG 2
CONCEPT OF KAIZEN
The term Kaizen originates from the
Japanese words, ‘Kai’ that means change,
whereas, ‘zen’ means for the better,
therefore, it means ‘change for the better’.

It signifies constant and gradual


improvement, no matter how small it is.

It should be taking place all the time in


every process, involving everyone from all
the ranks of management and the
workforce.
Total Quality Management - Spring
2010 - IUG 3
CONCEPT OF KAIZEN

In brief, Kaizen system includes:


 Total employee involvement starting from
top management;
 Empowering people;
 Listening to them;
 Promoting zero investment improvements;
and
 Focus on efforts rather than results in
Kaizen evaluation and performance
appraisal.

Total Quality Management - Spring


2010 - IUG 4
Definition of KAIZEN

1. A selection of better means


or a better method for achieving
an objective.
2. An accumulation of small changes.

3. A corrective action under constraints.

Total Quality Management - Spring


2010 - IUG 5
KAIZEN TECHNIQUES
KAIZEN techniques consists of the
following steps:
 Identifying problem (s)
 Examining the problem (s)
 Finding ideas to solve the problem (s)
 Developing selected proposal (s)
 Implementing the proposal (s)

Total Quality Management - Spring


2010 - IUG 6
KM 7

Multiple KAIZEN ideas

Problem:
 The man cannot reach
the tool box on the
shelf.
 Man is too short to
reach the tool box.

 The tool box is placed too


high.
Total Quality Management - Spring
Idea source: The Japan HR association 2010 - IUG
The interaction between man and tool
box generates a problem.

Tool
Box
Man
Problem
Problem does not exit.

Tool
Box
Man
Total Quality Management - Spring
2010 - IUG 8
Multiple KAIZEN ideas

 From “man “ stand point,


 cannot reach Use footstool.

From “toolbox” stand point,


 place it at the lower shelf.

Total Quality Management - Spring


2010 - IUG 9
Solution

Place the toolbox


at a lower shelf

Footstool

Total Quality Management - Spring


2010 - IUG 10
KM 11

 Problem:

A man broke a cup at a sink.

Total Quality Management - Spring


Idea source: The Japan HR association
2010 - IUG
Interaction

Cup

Sink Man

Way of
washing
Total Quality Management - Spring
2010 - IUG 12
Components Nature Solution
Cup Easy to break Plastic cup
Man Careless Caution
Method Easy to slip Wear rubber gloves
Sink Solid surface Place rubber mat

Total Quality Management - Spring


2010 - IUG 13
Cause and effect diagram

Man Method

Wash with hands


Carelessness
Wash quickly Wash together
My way

Cup
broke
Hard bottom Breakable materials
Deep
Weak against heat

Sink Cup

Total Quality Management - Spring


2010 - IUG 14
KAIZEN Steps

- Abolition
- Discontinuance
- Exclusion
- Removal

- Simplification
- Centralization
- Synchronization
- Standardization
- Management for exceptions
- Integration
- Combination
- Alternation
- Exchange
- Conversion
- Diversification
- Separation
Total Quality Management - Spring
2010 - IUG 15
Different styles of change

1. Small change --- By individual effort, a better way of


proceeding a job is considered.
(KAIZEN) (Idea creation)

2. Medium change --- By group effort, a better way is


proposed by following
(Small group activities) predetermined steps (or rule).

3. Big change --- By investments in new technology or


equipment, dramatic alterations are
(Innovation) achieved.

Total Quality Management - Spring


2010 - IUG 16

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