KAIZEN
WHAT IS KAIZEN?
• Kaizen is a very simple concept, formed from two
Japanese characters:
– “kai”, meaning “change”; and
– “zen”, meaning “good”.
• Therefore, “kaizen”, means, “change for the better”, or
“continuous improvement”
The creator of the concept of kaizen, was the late Dr. W. Edwards
Deming, an American statistician who made many visits to Japan
in the years following World War II
• Kaizen is based on the belief that the people doing a
particular job will often know better than everyone else,
including their superiors, how that job can be improved;
and that they should be given the responsibility for
making those improvements.
• The production area is by no means the only area within
a company where kaizen can be implemented.
• Every department within a company can make continuous
improvements in its operations by making small changes on a
daily basis.
• The first step in the process is to break down all
communication barriers between the various units within the
company.
• The master budget is one such tool that can be used to improve
coordination and communication between all of the
departments or other subunits within a company.
Definition
• Kaizen approaches productivity improvement.
• In Japanese, Kaizen means “small, incremental,
continuous improvement,” and
• The English translation is “continuous or continual
improvement.”
• Kaizen may be defined as the “the systematic organized
effort to continuously improve the performance at the
work area by individual effort in a group who assemble
periodically to discuss their work related problems.”
• It is a process that, when done correctly,
– humanizes the workplace,
– eliminates unnecessarily hard work (both mental
and physical),
– teaches people how to do rapid experiments
using the scientific method, and
– how to see and eliminate waste in business
processes.
Need for Kaizen
• People alone can think, rethink and implement
improvements. No other resource is capable of
thinking.
• We are in highly constraints atmosphere viz.
– Cost up and price down pressure, customer is
demanding
– Depressed operating margins
– Product / process obsolescence at speed
• If we change, can get better. If we continue
without change, can get worse.
Objectives of Kaizen
• Eliminating activities that add cost but not value.
• Develop a problem solving culture
• Elimination of waste
• Smoothing processes
• Making the job safer and easier
• Improving quality
• World class performance
• just-in-time delivery
• production load leveling of amount and types
• standardized work
• paced moving lines and right-sized equipment
• Basically, Kaizen takes processes, systems, products, and
services apart then rebuilds them in a better way.
• Kaizen goes hand-in-hand with that of quality control
circles, although it is not limited to quality assurance.
Process of Kaizen
• Identify specific point for improvement in ones own work area.
• Analyze the root cause of the problem and develop solution.
• Implement the kaizen and quantify benefits.
• Standardize the improvement through proper documentation.
• See if there is scope for horizontal deployment.
• Fill in the improvements in the standard format and submit for
evaluation.
• Audit after 3 months for holding gains.
Common area of kaizen
• Kaizen improvement in work method
• Defining Work method
• Quality of products
• Reducing waste or defective products
• Saving power and fuel
• Saving time and space
• Reducing inventory and house keeping
Benefits of Kaizen
• Kaizen is focused on making small improvements on a
continuous basis.
• Kaizen involves every employee in making change—in
most cases small, incremental changes.
• It focuses on
– identifying problems at their source,
– solving them at their source, and
– changing standards to ensure the problem stays solved.
• It's not unusual for Kaizen to result in 25 to 30 suggestions
per employee, per year, and to have over 90% of those
implemented.
• These continual small improvements add up to major
benefits.
• They result in
– improved productivity,
– improved quality,
– better safety,
– faster delivery,
– lower costs, and
– greater customer satisfaction.
Results of Kaizen
• Kaizen Reduces Waste in areas such as inventory, waiting
times, transportation, worker motion, employee skills, over
production, excess quality and in processes.
• Kaizen Improves space utilization, product quality, use of
capital, communications, production capacity and employee
retention.
• Kaizen Provides immediate results. Instead of focusing on
large, capital intensive improvements,
• Kaizen focuses on creative investments that continually solve large
numbers of small problems. Large, capital projects and major changes will
still be needed, and Kaizen will also improve the capital projects process,
but the real power of Kaizen is in the on-going process of continually
making small improvements that improve processes and reduce waste.
• On top of these benefits to the company, employees working in Kaizen-
based companies generally find work to be easier and more enjoyable—
resulting in higher employee moral and job satisfaction, and lower turn-
over.
Lecture Video Link:
https://
classroom.google.com/w/OTY2MTg4NTI1NTRa/tc/MTE1OTMxMjI2Mzgz
Demo Video Link:
https
://classroom.google.com/w/OTY2MTg4NTI1NTRa/tc/MTE1OTMxMjI2Mzgz
Quiz Link:
https
://docs.google.com/forms/d/e/1FAIpQLScbQx7-SCwpM4yEoEhf5bDCzckOGP
GiyHH4XcyR-8zFrgcH7Q/closedform
Assignment Link:
https://classroom.google.com/c/OTY2MTg4NTI1NTRa/m/MTE1OTIyODMw
MTMx/details
