KAIZEN

BY,
NIKHILA DORA
 INTRODUCTION…
 Kaizen was known as continuous improvement. It is a
japanese management concept for continuous incremental
change.
 Kaizen is actually a life philosophy assumeing that every
aspects of life constantlyimproved.
 It lies behind many japanes mgmt concepts such as total
quality control, quality circle, small group activities and
labour relations.
 Kia- change and zen- good.
 it is originated in toyota motor company as part of lean
manufacturing. Taiichi ohno developed the toyota production
system through kaizen. Many concepts have come from
industrial engineering & dr. edward deming’s teaching.
 It is a continuous improvement focusing on
eliminateing waste in all system and process of
an organization. It begins and ends with
people.
 In kaizen an involved leadership guides people
to continuously improve their ability to meet
expectations of high quality, low cost and on
time delivery. Transforms company into
superior global competitors.
 New meaning in 1990’s- it is a structured method of
continuously improving process usually taking 3-5
days to complete. Now it is known as kaizen events.
Methods of kaizen that target a particular area or
segment of the production change.
 Kaizen event consists of a team of 6-10 participants
from all departments spending 2-5days collecting,
studying and analyzing data brainstorming and
implementing the improvement to the process.
Should be implemented by the lower or middle
management with the support of top level
management.
 Kaizen has two elements namely
“improvement/ change for the better” and
“ongoing/continuity”.
 In an organization three things viz.
maintenance, innovation and kaizen should
happen simultaneously for its better results.
KEY ELEMENTS OF KAIZEN…
 Key elements of kaizen are quality, effort,
willingness to change and communication. The
foundation of kaizen elements which are
teamwork, personal discipline, improved
morale, quality circle and suggestion for
improvement. Out of these three factors which
arise are listed below:
1. Elimination of waste and inefficiency.
2. Kaizen 5s frame of good housekeeping.
3. Standardization.
Elimination of waste and inefficiency…
 Overproduction: produceing more than the customers
needs right now.
 Transportation: movement of product that does not add
value.
 Motion: movement of people that does not add value.
 Waiting: idle time created when material, information,
people or equipment is not needed.
 Processing: efforts by the organization in different forms
that adds no value from the customers’ viewpoint.
 Inventory: stock on hand quantities of material..
 Defects: work that contains errors, rework, mistakes or
lack something which is necessary.
 Kaizen 5S framework for good
housekeeping…
 Seiri (sort/tidiness)
 Seiton (systematize/orderliness)
 Seiso (cleanliness/sweep)
 Seiketsu (standardized clean-up)
 Shitsuke (self-discipline)
 Standardization…
 Helps organization to manufacture items with
discrete shape and size. This in turn minimizes
the efforts in planning and scheduleing while
manufacturing the items. simplifies the
stocking procedure at the store of dealer.
 Classification of kaizen…
 Kaizen workshop
 Kaizen blitz

 Kaizen events

All the 3 are team based rapid improvement

workshops.