Kaizen ?Kai = Change Zen = Good (For the better) Kaizen = Continuous Improvement` ( Elimination of Waste)
InceptionEvolved after World War II, influenced by American’s ExpertsDeveloped by Maaski Imai(The Key to Japan’s Competitive Success (1986)First applied In Toyota Production System
Building Blocks• Elements Teamwork, personal discipline, Improved Morale, Quality Circle, Suggestion for improvement• Concept PDCA,5S, Quality Circle and Just in time Production• Role Players Top, Middle and lower level Management• Approach Management, Group and Individual Oriented Kaizen
Under One RoofJust In time Quality Circle Value Stream MappingZero defects Total Quality Control 5SQuality Improvement Six Sigma RoboticsQuality Improvement Automation Customer OrientationTotal Productive Maintenance New product Development
Process Standardize operation Measure Standardize currentnew methods operation Compare Innovate to measures meet with requirements requirements
A Big PictureKey Benefits 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 Higher operational efficiency• Reduces wastage, like inventory waste, time waste, workers motion Improves space utilization and product quality• A Learning Experience – Every member of a Kaizen Team will walk away from the event learning something new.• Encourages big picture thinking Results in higher employee morale and job satisfaction, and lower turn-over.
In a nutshell Get Rid Of All Old Assumptions. Dont Look For Excuses, Look For Ways To Make Things Happen. Say "No" To The Status Quo. Dont Worry About Being Perfect - Even If You Only Get It Half Right " Start Now! It Does Not Cost Money To Do Kaizen. If Something Is Wrong "Fix It Now. Good Ideas Flow When The Going Gets Tough. Ask "Why" Five Times - Get To The Root Cause. Look For Wisdom From Ten People Rather Than One. Never Stop Doing Kaizen.