PREPARED BY :-

ACHAL DUGAR MAYANK SINHA PRIYANSH ACHARYA

SHIMONA SIWATCH CHINMAYA RANJAN RAY
 KAIZEN- AN INTRODUCTION
• Masaaki Imai is
known as the
developer of Kaizen.

• 改 ('kai') KAI means

'change' or 'the
action to correct'.

• 善 ('zen') ZEN
means 'good'
• So basically kaizen is small incremental
changes made for improving productivity
and minimizing waste.
• Kaizen has three main principles:

• Consider the process and the results!

• The need to look at the entire process of the job at
hand and to evaluate the job as to the best way to get
the job done.
• Kaizen must be approached in such a way that no
one is blamed and that the best process is put into
place.
 FEATURES 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!!!

• A Learning Experience – Every

member of a Kaizen Team will walk
away from the event learning
something new! !
• Team based & cross functional –
Team members can be from
various functions of the business.
Top management participation is
encouraged.
PHASES IN KAIZEN
 THESE STEPS ARE SHORTEN
INTO :

A.) Select an Event

B.) Plan an Event

C.) Implement an Event

D.) Follow-up to an Event

 BENEFITS OF KAIZAN
• Kaizen Reduces Waste- like
inventory waste, time waste,
workers motion
• Kaizen Improves space
utilization, product quality
• Results in higher employee
moral and job satisfaction, and
lower turn-over.
• Toyota is well-known as one of the
leaders in using Kaizen. In 1999 at
one U.S. plant, 7,000 Toyota
employees submitted over 75,000
suggestions, of which 99% were
implemented.
 Varieties of Kaizen Methods
• Individual Versus Teamed

• Day-to-Day Versus Special Event

• Process Level Versus Sub process

Level
 5 ‘S’ in KAIZEN
• 5S is a method for organizing a
workplace, especially a shared
workplace (like a shop floor or an office
space), and keeping it organized.

• To take the concept of Kaizen performance to its

ultimate level of simplicity, it offered the following
"5S" steps
• Sorting keeping only
essential items
• Simplifying eliminates extra
motion.

• Sweeping keep the

workplace clean
• Standardizing standardized work practices
• Sustaining maintaining and reviewing
standards
 PIT FALLS IN KAIZEN
• Resistance to change

• Lack of proper
procedure to implement

• Too much suggestion

may lead to confusion
and time wastage