Contents

Introduction.................................................................................................................................................2
What is Kaizen?.......................................................................................................................................2
Brief History of Kaizen...........................................................................................................................2
The Types of Kaizen.....................................................................................................................................3
System Kaizen..........................................................................................................................................3
Process Kaizen.........................................................................................................................................3
How to Implement Kaizen...........................................................................................................................3
Kaizen 8 steps..........................................................................................................................................3
Tips When Implementing Kaizen.............................................................................................................4

Page 1 of 4
Introduction
The business world is always changing for the better. That means no matter how good your
business is doing, there is always room for improvement. To make your company more efficient
and productive, you need to implement Kaizen—a continuous improvement process. Kaizen is a
key component of Lean Manufacturing and involves the steady removal of waste from the
production line.

This guide will teach you everything you need to know about Kaizen—from the basics to how
you can successfully drive continuous improvement in your organization. Let’s get started!

What is Kaizen?
Kaizen is a Japanese term that means “improvement” or “change for the better.” It is a business
philosophy that focuses on continuously improving processes to achieve optimum efficiency.
Kaizen revolves around the following principles:

 Eliminating waste
 Continuous improvement
 Respect for people
 Quality first

The kaizen philosophy can be applied to any business area, from manufacturing and production
to office work and sales. It is a holistic approach that involves everyone in the organization, from
the CEO to the front-line workers.

Brief History of Kaizen

The use of Kaizen can be traced back to post-World War II when Japanese businesses were
trying to rebuild the country’s economy. Kaizen was first implemented in manufacturing, but it
quickly spread to other sectors as businesses realized the benefits of continuous improvement.

In 1955, as one of the initiatives of the Japan Productivity Center, Japanese delegates officially
started visiting the United States to study American management practices. They also brought
with them the Kaizen philosophy.

In the 1980s, Kaizen gained popularity in the West after business leaders such as Peter Drucker
and W. Edwards Deming began writing about it. Masaaki Imai’s 1986 book entitled “Kaizen:
The Key to Japan’s Competitive Success,” also contributed to the further popularization of the
concept outside of Japan.

Kaizen was adopted by many American businesses, including Ford Motor Company and General
Electric. Soon enough, Kaizen became known as a global best practice.

Page 2 of 4
The Types of Kaizen
Currently, there are two types of Kaizen:

System Kaizen
Also called “flow” kaizen. This type of Kaizen focuses on the overall value stream and how to
make it more efficient. System kaizen includes activities such as process mapping, value stream
analysis, and waste reduction. It optimizes the flow of the production system while performing
waste removal activities on the overall process.

A good example of system kaizen would be purchasing a new forklift to optimize two more
production stations and reduce the overall cycle time.

Process Kaizen
This kaizen type focuses on removing waste from individual processes and tasks. It is often used
to solve specific problems that are hindering productivity. Using the forklift example uses
process kaizen when the forklift operator moves some inventory around to allow faster loading
and unloading times.

How to Implement Kaizen

Kaizen 8 steps.
Kaizen is a journey, not a destination. It is a mindset that needs to be adopted by everyone in the
organization. From the top management to the front-line workers. Management should
relentlessly optimize the production process while reducing wastes that don’t add value to the
process.

Performing kaizen activities has a defined process. Here are eight steps that you should take to
implement Kaizen effectively:

1. Map the value stream: The first step is to understand the current value stream. This will
help you identify the kaizen opportunities.
2. Identify wastes: Once you have mapped out the value stream, it will be easier for you to
identify the wastes in the process. Seven types of waste are common in the manufacturing
processes: overproduction, waiting, transportation, motion, inventory, defects, and over-
processing.
3. Set kaizen goals: Once you have identified the wastes, you need to set kaizen goals.
These goals should be SMART (specific, measurable, achievable, relevant, and time-
bound).

Page 3 of 4
 4. Choose a process to optimize: Once you have set the kaizen goals, you need to select a
process to optimize. This is usually the process that impacts the bottom line most.
5. Implement the 5 S method: The next step is to implement the kaizen methodology,
which includes the five steps of Sort, Set in order, Shine, Standardize, and Sustain (also
known as the “Five S” method).
6. Look for the 7 types of Muda: The next step is to look for ways to eliminate the seven
wastes from the process. These wastes include overproduction, waiting, transportation,
motion, inventory, defects, and over-processing.
7. Design a process improvement plan: The next step is to design a process improvement
plan. This plan should include the kaizen goals, the process of optimization, and the
kaizen methodology. Implement the kaizen improvements swiftly to avoid meetings and
presentations, if possible.
8. Evaluate the results: The last step is to evaluate the results of kaizen implementation.
This includes looking at the financial impact of Kaizen and the impact on quality and
productivity. Also, compare the results to the original values to ensure that Kaizen
provides the intended benefits.

Tips When Implementing Kaizen

Here are some tips that you should keep in mind when implementing Kaizen:

 Keep it simple: Do not try to tackle too many things at once. Focus on one process or
task and Kaizen that.
 Do not forget the people: The success of Kaizen depends on the people who are
involved in it. Make sure to involve everyone in the organization, from top management
to the front-line workers.
 Be persistent: Kaizen requires a lot of hard work and dedication. Do not give up if you
do not see results immediately.
 Be flexible: The kaizen process is flexible, so be prepared to change course if necessary.
 Celebrate successes: When you achieve kaizen goals, celebrate the success with
everyone involved. This will help motivate people to keep up the good work.

Page 4 of 4