改 ('kai') KAI means 'change' or 'the action to correct'.
善 ('zen') ZEN means 'good'
So basically kaizen is small incremental changes made for improving productivity and minimizing waste.
Kaizen has three main principles:
• Consider the process and the results! • The need to look at the entire process of the job at hand and to evaluate the job as to the best way to get the job done . • Kaizen must be approached in such a way that no one is blamed and that the best process is put into place.
FEATURES OF KAIZEN
Widely applicable – Can be used in both manufacturing and non-manufacturing environments
Highly effective & results oriented . Kaizen events will generate
quick results, Measurable results, Establish the baseline, and measure the change!!!
A Learning Experience – Every member of a Kaizen Team will walk away from the event learning something new! !
Team based & cross functional – Team members can be from various functions of the business. Top management participation is encouraged.
THE STEPS OF KAIZEN ARE : A.) Select an Event B.) Plan an Event C.) Implement an Event D.) Follow-up to an Event
BENEFITS OF KAIZAN
Kaizen Reduces Waste- like inventory waste, time waste, workers motion
Kaizen Improves space utilization, product quality
Results in higher employee moral and job satisfaction, and lower turn-over.
Toyota is well-known as one of the leaders in using Kaizen. In 1999 at one U.S. plant, 7,000 Toyota employees submitted over 75,000 suggestions, of which 99% were implemented.
Varieties of Kaizen Methods
Individual Versus Teamed
Day-to-Day Versus Special Event
Process Level Versus Sub process Level
5 ‘S’ in KAIZEN
5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized.
To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following "5S" steps
Sorting keeping only essential items
Simplifying eliminates extra motion .
Sweeping keep the workplace clean
Standardizing standardized work practices
Sustaining maintaining and reviewing standards
PIT FALLS IN KAIZEN
Resistance to change
Lack of proper procedure to implement
Too much suggestion may lead to confusion and time wastage