What is Kaizen (Continuous Improvement)?

What is the Kaizen Event?

What is the kaizen process?

Identify Problem Analyze the problem Develop an optimal solution Implement the solution Study and analyze the results Standardize the solution

What are the 3 pillars of kaizen?

Good House Keeping & 5S Waste (Muda) Elimination Standardize

History:

What are the 5 elements of kaizen?

Teamwork Personal discipline Improved morale Quality circles Suggestions for improvement

Principles of Continuous Improvement:

Kaizen Umbrella:

5W 1H of Kaizen:

→ Kaizen comes from the Japanese words “kai” which means “change or improvement” & “zen” which means “for betterment.”→ Its popular meaning from Toyota is “continuous improvement” or “small incremental improvements” of all areas of a company, not just manufacturing.→ It is a very famous Lean Manufacturing tool.→ A Kai-Zen event should be part of an overall program of continuous improvement and It based on many small changes rather than fundamental changes. It does not require major capital investment or major process changes. The fundamental changes are related to Research and Development.→ As the ideas come from the workers themselves, they are easier to implement.→ All employees should continually be seeking ways to improve their own performance.→ It helps encourage workers to take ownership of their work and can help reinforce the team working, thereby improving worker motivation.→ It is a very famous tool in Lean Manufacturing.→ The Six Steps of the Kai-Zen process is mentioned below→ The Key Criteria are:⇢ Does It reduce waste, Improve Quality, or Increase Safety?⇢ Similarly, Does It Address the Root Cause?⇢ Does It relate to Standardize?→ After World War II when Toyota first implemented quality circles in its production process.→ This was influenced in part by American business and management teachers who visited the country.→ A Quality Circle is a group of workers performing the same or similar work, who meet regularly to identify, analyze, and solve work-related problems.→ This revolutionary concept became very popular in Japan in the 1950s.→ The term Kai-Zen actually became famous around the world through the works of Masaaki Imai.→ Masaaki Imai is a Japanese organizational theorist and management consultant, known for his contribution to the betterment of industries.→ He published two fundamental books on business process management→ Improve everything continuously.→ Eliminate old and traditional concepts.→ Accept the things, no give any excuses and make things happen.→ Don’t Assume New Methods Will Work.→ If something is wrong then correct it.→ Empower everyone to take part in problem-solving.→ Get information and opinions from multiple people.→ Before making decisions, ask “why” 5 times to get to the root cause (5 Why Method) or we can usefor root cause analysis.→ Be economical.→ Never stop trying to improve→ The elements of the Umbrella is:01. Total Quality Control (TQC)02. Quality Circle03. Suggestion System04. Automation05. Discipline in the Workplace06. Customer Orientation07.08. Robotics09. Kanban10.11. Just in Time12. Zero Defect13. Small-Group Activity14. Management Relations15. Productivity16. New Product Development→ The goal is production without wastes by improving standardized activities and processes.→ Industrial engineer Taiichi Ohno, father of the Toyota Production System (), noticed that there is an 80% loss in every process and the value of the process is less than 20%.