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Kaizen: The Continuous Improvement Programme

Kaizen is a Japanese philosophy of continuous improvement. It means "change for the better" through gradual, orderly processes that eliminate waste. The key aspects of Kaizen are focusing on eliminating waste through improving systems and processes, valuing employees and creativity, and making small continuous improvements. Some techniques used in Kaizen include identifying the seven types of waste, reducing non-value added activities, setting goals for regular improvement ideas, and using tools like 5S, standardization, and eliminating muda. Breaking old habits and fully engaging employees can be challenges to implementing an effective Kaizen program.

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39 views

Kaizen: The Continuous Improvement Programme

Kaizen is a Japanese philosophy of continuous improvement. It means "change for the better" through gradual, orderly processes that eliminate waste. The key aspects of Kaizen are focusing on eliminating waste through improving systems and processes, valuing employees and creativity, and making small continuous improvements. Some techniques used in Kaizen include identifying the seven types of waste, reducing non-value added activities, setting goals for regular improvement ideas, and using tools like 5S, standardization, and eliminating muda. Breaking old habits and fully engaging employees can be challenges to implementing an effective Kaizen program.

Uploaded by

hr4ever
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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KAIZEN

The Continuous Improvement


Programme.
CONCEPT
• “Kai” means “change”
• “zen” means “good (for the better)”
• Then, Kaizen means ‘change for the better’
or continuous improvement
• Gradual, orderly, and continuous
What Does Kaizen Mean?

KAI + ZEN
To modify, to change Think, make good, make better

= KAIZEN
Make it easier by studying it, and making the improvement
through elimination of waste.
To Ma ximise Profits (or Sta y in Busines s)

Elimina te Wa s te d Time
- Eve rywhe re

S hrink Le a d Time s
- Ga in a Compe titive E dge

Unlock Your P otentia l


FOCUS
• Eliminating waste
• Systems & Processes
• People
• Value on Individuals
• Value collective creativity
• Incorporates everybody
• Encourages anyone in thinking for ideas
• Low Cost
The Seven types of waste

7
Wastes
• Overproduction
• Delays (waiting time)
• Transportation
• Process
• Inventories
• Motions
• Defective products
Non Value Added
Activities

• Examine all Non Value added


activities in the Job for elimination.
Focus Kaizen on Reducing NVA
•Value-Add Activity

Non-Value-Add Activity

NVA Reduction is a Non Traditional Approach


Major Impact on Lead Time and QCD
Improvement Ideas
• Japan: 24 improvement ideas in writing per
employee each year

• U.S. companies: average less than one

• United Kingdom: one idea every six years


Are You Practicing Kaizen?

• When you have a problem, do you

a) try to tackle the whole thing


or
b) divide it into small manageable pieces?
Are You Practicing Kaizen?

• Do you try to fix the problem

a) perfectly from the beginning


or
b) make little improvements along the way?
Are You Practicing Kaizen?

• Do you

a) never deviate or stray from the


procedures that you have been taught
or
b) think of alternative methods for getting
the work done?
ISSUES
• Breaking the old habits
• New ideas/logic
• Cause of problem cultural
• Gemba
• Place where real action occurs
• Wet Blanket List
THE WET BLANKET LIST
• I am too busy to study it
• It's a good idea, but the timing is premature
• It is not in the budget
• Theory is different from practice
• Isn't there something else for you to do ?
• I think it doesn't match corporate policy
THE WET BLANKET LIST
• It isn't our business; let someone else think about
it
• Are you dissatisfied with your work ?
• It's not improvement, it's common sense
• I know the result, even if we don't do it
• I will not be held accountable for it
• Can't you think of a better idea ?
KAIZEN BUILDING BLOCKS
• 5S

• Standardization

• Eliminate Muda
Kaizen Implementation
• Study the job in detail
• Systematically examine all possibilities for
improvement using 5S, Poka Yoke, SMED Lean
etc.
• Submit your ideas in writing.
• Accept a token reward.
• ‘Team WAVE’ examines the suggestion
• Implement and Kaizen prepared.
• Accept reward in proportion to the profit.
Kaizen
• Thank you

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