KAIZEN

PRESENTED BY :- UTKARSH SINGH

SUMIT
AMIT
YAMINI
 Introduction 2
• Masaaki Imai is known as the developer of
KAIZEN.

• ‘KAI’ means ‘Change or the action to

correct’.

• ‘ZEN’ means ‘Good’.

• Kaizen is small incremental changes made for

improving productivity and minimizing wastes.
 10 Principles of KAIZEN 3

1.Never Stop
There is an area for improvement in everyone’s life, no matter how successful
they are. The idea here is to focus on continuous improvements in your life,
every day, no matter how small the step you take to be a better you than you
were yesterday.

2. Be Proactive
Stop hesitating because of possible hurdles that you predict, and move forward
toward your goal for continuous improvement. It is important to not take any
chance in the way of improvement, and for each person in the organization to
take personal responsibility for making improvements. While it is one thing to
sit around and discuss about the improvements that should be made, it is
different thing to actually make an action plan to implement the changes.
 3. Eliminate Old Practices
 The main part of avoiding complacency is getting rid of old
and tired traditions that are obsolete. Because we live in a
culture that continually making changes and improvements, it
is important for businesses to keep up with this in order to stay
relevant  for company’s continuous improvement
 4. Don’t Stop
 Never consider yourself to be finished. Improvement has no
limits, and can be proceeded on an infinite level. You can
always improve yourself. Whether it is learning something
new useful things or perfecting a skill you already have, there
is opportunity to get better in everybody’s life for continuous
improvement.
 5. Make Corrections
  Some Part of the trial-and-error process requires making
corrections to practices or processes that have a major issue with
them. It is critical to continue to make corrections all through the
process in order to continuous improvement. To Start some new
habits to correct the things that you may have been doing wrong
up until this point.
 6. Empower All Employees to Speak Up
 Everyone who is associated in the success of the company—from
the CEO to the line workers—should be encouraged to offer
suggestions and solutions for problems that can be fixed, or
improvements that can be made.
 7. Don’t Assume New Methods Will Work
 Just because a method is new does not mean that
it is improved. It is main things to move far
beyond the status quo in order to be effective in
business. This will probably require trial and error
until achievement is accomplished.

 8. Practice the “Five Why” Method

 Before making any final decisions, get to the root
of the problem by asking “why?” five times. By
continuing to ask yourself “why?” you are likely to
find the genuine purpose behind a problem.
 9. Be Economical
 Watch your finances during the whole process of making an
improvement. Look for ways to save money while making small
improvements, and then spend the saved money on further
improvements.A common goal of improvement is to save money
or stop spending so much money on unuseful Things. And stop
buying them.

 10. Crowdsource
 Learn from other people and get some new opinions on things
you can add to your routine to create continuous improvement.
Before making a change or possible improvement, Talk with
different  people about what they are doing in their daily life  to
improve themselves.
Features Of Kaizen 8

• Widely applicable.

• Highly effective and result oriented.

• A learning experience.

• Team based and cross-functional.

Phases in Kaizen 9

A. Select an event.

B. Plan an event.

C. Implement an event.

D. Follow-up an event.
Kaizen 10
Elements
5’S’ in KAIZEN 11

• Sorting.

• Simplifying.

• Sweeping.

• Standardizing

• Sustaining.
 Seiri – Sorting. Keep the necessary in work area, dispose or
keep in a distant storage area less frequently used items,
discard unneeded items.
 Seiton – Systematic Arrangement for the most efficient and
effective retrieval. There should be a place for everything and
everything should be in its place. The place for each item
should be clearly labeled or demarcated. Items should be
arranged in a manner that promotes efficient workflow, with
equipment used most often being the most easily accessible.
Workers should not have to bend repetitively to access
materials.
 Seiso – Shining. Clean the workspace and all equipment, and
keep it clean, tidy and organized. After the first thorough
cleaning when implementing 5S, daily follow-up cleaning is
necessary in order to sustain this improvement. A “Shining”
work environment will lead to great efficiency gains.
 Seiketsu – Standardizing. Work practices should be
consistent and standardized. Work stations for a particular
job should be identical. All employees doing the same job
should be able to work in any station with the same tools
that are in the same location in every station. Everyone
should know exactly their responsibilities.
 Shitsuke – Sustaining. Once the previous 4 S’s have been
established, they become the new way to operate. Maintain
focus on this new way and do not allow a gradual decline
back to the old ways. The effect of continuous improvement
(Kaizen) leads to less waste, better quality and faster lead
times.
 Benefits Of Kaizen 14

Worthy targets
Kaizen as a method of improvement is not only beneficial to the
business. It is also beneficial to employees, customers and the
organization as a whole. This management theory is applicable
to most types of businesses. Kaizen recognizes and rewards the
efforts of employees. By so doing, it gives them a sense of
worth in the organization.

Improved teamwork
One of the major kaizen advantages is improved teamwork.
Kaizen is a quality improvement tool driven by teamwork. It
does not benefit only a selected few, but everyone involved in
the business process. As the kaizen team solves problems
together, they develop a bond and build team spirit. Thus,
employees are able to work with a fresh perspective, an
unbiased mind and without prejudice.
 Kaizen builds leadership skills
 Every kaizen team must have a team leader.
The team leader is responsible for organizing
the kaizen team and coordinating
implementation. The kaizen team leader makes
sure that everyone is performing their roles
successfully.
 Improved efficiency
 A major kaizen advantage is improved
efficiency. Kaizen improvements boost the
quality of services. It helps businesses
implement new process improvements, boost
efficiency and enhance time management.  For
example, Toyota Manufacturing Company
employs kaizen in its production process.
 Improved Standard Work Document
 Implementing changes during kaizen results to a new
and improved Standard Work Document. Standard
Work Document, also called standardized work, is a
tool that forms the foundation of kaizen
improvements. It contains the current best practice
guiding a business. Sometimes, this is the main aim
of implementing kaizen. In addition, Standard Work
Document serves as the base for future
improvements.
 Improved employee satisfaction
 Another kaizen advantage is that it improves
employee satisfaction. Kaizen involves the employees
when implementing changes for improvements.
Employees can make suggestions and creative input
for changes through a suggestion system like team
meetings. When employees are involved in decision
making, it gives them a sense of belonging and
worth.
 Better safety
 Improving safety on the work floor is a kaizen
advantage for business. Safety is improved when
businesses implement ideas that clean up and
organize workspace. By so doing, employees have
better control of business process equipment.
Employees are also encouraged to make suggestions
to improve safety on the work floor. This helps to
minimize accidents and other related injuries.
 Waste reduction
 Kaizen reduces wastes in business processes. This is
another major kaizen advantage. Kaizen is the
responsibility of everyone. Therefore, management
and staff are responsible for identifying areas that
constitute waste in the business process. By
implementing constant changes, they can determine
the root cause of wastage and fix them.
KAIZEN DISADVANTAGES
 Difficult to implement in existing systems
 Despite the many benefits of kaizen, there are
some limitations business managers need to be
aware of before deciding to implement it. This is
because implementing kaizen is tantamount to
altering current management systems. As soon
as kaizen is implemented in an organisation, it
is very difficult to return to old management
systems.
 Change is difficult
 One of the greatest kaizen disadvantages is that
people are always reluctant to change.
Therefore, when businesses want to implement
kaizen, they have to put up with a certain
resistance. Employees might not be ready to
accept a different system from what they have
been used to.
 Could cause frictions
 In addition, when implementing kaizen, could be
very difficult for some organisations to change
their current approach to work. Hence, if a
business is not prepared for change when
implementing kaizen, it could lead to friction.
 Training requirement
 Another kaizen disadvantage is the method of
training. The kaizen methodology requires training
staff and management to understand and adopt
the kaizen philosophy. This might require altering
the usual process of work.
 Enthusiasm could wane easily
 Employees might be excited at first to
implement changes. However, their excitement
could wear away when the changes become
difficult to adapt to. As such, they may resort to
old practices and stick to ‘business as usual’. In
addition, employees could be demoralized and
unenthusiastic about work.
THANK YOU