History of Kaizen
Masaaki Imai introduce term Kaizen also known as gemba kaizen. Kaizen the key to Japan’s Success.
Kaizen improvement are small and incremental. Kaizen Process bring dramatic result over a period. Kaizen is a concept to bring out continual improvement to reduce cost.
The kaizen concept explains why companies cannot remain stable for long in Japan. Western country did major changes in management practice and technological up-gradation. whihc was more popular and attention seeker. On the other hand, Kaizen is often undramatic and subtle. Common idea and cost effective solution is kaizen. Kaizen is also a low-risk approach.
What is Kaizen?
The word Kaizen in Japanese is written with two characters meaning “to change” and “for the better.” From 1644 to 1911, in China, the word Kaizen is Chinese in origin and has popular as far back as the ‘Qing dynastic period’.
the term kaizen always means improvement. It was not use exactly earlier as we are using now for, kaizen 5s, lean manufacturing. Kaizen become part of Toyota production system in 1960. Kaizen course introduced in after 1960. The kaizen course helped Toyota production system to improve process performance.
Types of Kaizen
There are various types of Kaizen. The term “Point Kaizen” or “Kaizen Event” of “Kaizen Training” are well-known types of kaizen.
Believe it or not, the term “Point” as in “Point Kaizen” has significance. Also, the condition Before Kaizen and After Kaizen have meaning.
The term “Point” illustrates the approach to Kaizen, as well as what might be described as a Lean Maturity. I don’t like the term “Lean Maturity”, but it’s descriptive when taken in context
Kaizen implementation benefit
Cost reduction through reducing waste and providing better quality at competitive pricing.
For Supply chain : Improving production and efficiency through Kaizen implementation in daily operations. Empowering employees who can identify problems and applying Kaizen actions immediately.
The objectives of Kaizen and the Kaizen Division are summarized as follows:
- Continuous improvement for the organization. er, space, equipment,
- Continuous improvement for the organization.
- Cost reduction and cost optimization to save manpower, space, equipment, material.
- Continuous training and education for the employees of the organization
- Increased productivity of the employees in the organization.
Kaizen tools and principals
- Observe and sort out value added, non value added and necessary non value added.
- Fundamental stick to pull production and not on push system.
- Use single piece flow in kaizen.
- The Documentation of Standard Operating Procedures (SOP).
- 5s kaizen is best kaizen that help you get good 5s System implementation.
- Visual management through or visual control For better safety, better information and to avoid operating errors.
- When facing a problem or even a mistake, there is a principle to grasp problems, analyze the root causes, and then follow the problem-solving process. Therefore, to prevent problems, the following steps should be considered
- Be sure to follow the standard operation and instruction (work procedure and work sequence).
- Carry out the work completely and correctly.
- Do a perfect job.
- Concentrate on the work
- Make sure to ‘STOP’ ‘CALL’ and ‘WAIT’ in case of an emergency.
Steps of implementation of Kaizen
Step — 1 — Discover the improvement potential
Identified the Scope of improvement. It could be any of 7 waste in process. This can be taken by process observation, Customer complaint or as suggestion. Even 5s can identify some of kaizen (You can call 5s kaizen.
Step — 2 — Analyze the present method
In this step of kaizen implementation, you have to analyze the present method in detail. Break down your process in a small group of activity. Study each activity and define the activity in 3 part
· Value added
· Non value added
· Necessary Non- value added.
Step — 3 — Generate ideas- suggestion taken
Take suggestion from each level or team member. Even you can collect ides by brain storming. Gemba is effective idea for improving waste. Make sure Every one is involve.
Step — 4 — Develop an implementation plan
Prepare implementation plan. Assign responsibility along with required authority to each person. Put a dead line for each activity and keep checking it on regular interval. You must get the desired result in the time frame.,
Step — 5 — Implement the plan
Phase wise implementation will be done and tracked. Fix time for conducting implementation of kaizen. Many time team mates are not able to find time from the routine production. As kaizen gets delayed people loss their motivation.
Step — 6 — Evaluate the new method
Once you have implemented kaizen in your company you can opt for finding newer ideas to make it better. This is actually endless process. One has to keep doing it and keep improving it.
How do we help you?
Greendot help you in many way to improve your company waste. We have track record of 1000 plus clients. With kaizen continuous improvement you can optimize cost.
Our expert kaizen consultant can help you to
- identification of kaizen
- Kaizen training
- Kaizen 5s concept introduction
Our consultation will be result oriented and you can track the cost of improvement.
We like to demonstrate some of the kaizen example that bring cost improvement by waste elimination. Please refer to the