KM 1

KAIZEN
Management
Characteristics of
Japanese Production Systems

KAI-ZEN

Continuous improvement

KM 2

V:Green walking

KM 3

What is Industry ?
Input

Output
Industry

Man-power
Machines
Materials
Methods Technology
Skill
(4Ms)

Products
Services

KM 4

Evaluation of the output ?

Q, C, D
Input

Output
Industry

Q: Quality
C: Cost
D: Delivery

KAIZEN
action

KM 5

KAIZEN is a feedback
Input

Output
Industry

KAIZEN
action

KAIZEN is a corrective action

KM 6

KAIZEN is a Japanese word

:
change
: better

KM 7

Definition of KAIZEN

KM 8

Definitions of KAIZEN
1. A selection of better means or
a change of current method
for achieving an objective.
2. An accumulation of small changes
The Japan HR Association

KM 9

How do farmers pack

oranges?

KM 10

I need
help.

KM 11

Productivity: 1 net per min.

KM 12

KM 13

Productivity: 5 nets per min. with 2 workers

KM 14

A selection of better means or

a change of current method
for achieving an objective.

Can you think of a better

method to pack oranges?

KM 15

Productivity: 5 nets per min. with 1 worker

KM 16

Definitions of KAIZEN
1. A selection of better means or
a change of current method
for achieving an objective.
2. An accumulation of small changes
The Japan HR Association

Chopsticks

KM 17

KM 18

Children hold their chopsticks improperly

KM 19

KM 20

Training

but still difficult to use

KM 21

Soft paddings (Japanese fish paste)

for some children, balancing the chopsticks is difficult

KM 22

Training chopsticks

KM 23

KM 24

KM 25

KAIZEN is
a continuous improvement
Continuous = again and again

KM 26

Question

KM 27

Where is
between
KAIZEN
is aa division
small change
to
our
jobssomething
and KAIZEN?
make
better.
- I picked up a garbage and
put it in a trashcan.
- I wiped the windows and
made them clean.
- I used a mop to clean the gasoline
left on the floor.

KM 28

A waitress was working

at a restaurant in Tokyo

KM 29

KAIZEN is a small change

A small change of a method (approach)

Any way to pick up the mop?

Any way to store the mop?
Any way to carry the mop?

KM 30

KM 31

KM 32

KM 33

toothbrush

KM 34

Swatter

KM 35

tweezers

KM 36

KM 37

Improvement by
changing methods
How do we change methods?

KM 38

KAIZEN Steps

KAIZEN Steps

KM 39

KAIZEN Steps Review

KM 40

Elimination

Remove thisKM 41
sliding door

What is the use of the sliding doors?

KM 42

Why are shoe box doors needed?

Before

After

KM 43

Why is the toilet cover needed?

Before

After

CDG(Paris)

Hong Kong

Toilets

KM 44

Frankfurt

Tokyo

KM 45

No sleeves down-jacket is easy to work

Before

After

KM 46

Reduce

A fluorescent light
bulb was removed.

Reduce the number of lights

KM 47

Before

Why two bricks?

Parking Lot

KM 48

KM 49

One brick is enough to stop a car

Before

After

KM 50

Zebra Zone

KM 51

Side lines of
the zebra zone
are removed.
Before

After

Long or short brush part?

Before

After

KM 52

KM 53

toothbrushes

KM 54

Change

Ribbon waving?

Visual Management

KM 55

KM 56

Pinwheel
turns around

Visual Management

The hollow about the key hole

smoothes the key movement.

KM 57

Before
After

To oil the pan, a small teapot is

more convenient than a ladle.

Before
After

KM 58

KM 59

KM 60

Stairways at the railway station

should have signs of up and
down.

Before
After

KM 61

At
AtJR
JRKurume
KurumeStation
Station

KM 62

KM 63

Rush Hour

KM 64

Before
After

KM 65

Hanging Straps in JR trains

KM 66

Hanging strap in
Hong Kong subways

The Japan HR Association

KM 67

Suggestion System
vs.
KAIZEN Suggestion System

Suggestion System
You suggest your ideas, and I will
examine them and implement some
of your ideas later.

KM 68

Idea

Idea

Reward

Suggestion System Concept

KM 69

KM 70

KAIZEN Suggestion System

Implemented KAIZEN ideas must be
submitted

N
IZE
A
K
et
she

KM 71

Suggestion System
Workers
responsibility

Management responsibility
Idea

generation

Workers responsibility

Management
responsibility

KAIZEN Suggestion System

KM 72

Suggestion System
Propose improvement ideas for any
activity in the company.

KAIZEN Suggestion System

Propose only improvement ideas
which will improve your own work.

KM 73

KAIZEN
Memo

AOTS KAIZEN

KM 74

KM 75

AOTS KAIZEN

Reward

KM 76

For an excellent KAIZEN, a large amount of

reward is given (5000 yen, 10000 yen, 50000 yen)

Award Payment for Each

KAIZEN Suggestion (2008)

Average 385 yen

Surveyed 528 companies

KM 77

KM 78

Among (527) companies,

2008

Employees who suggested at lease one idea

Total number of employees

74.4%
Implemented suggestions
All suggestions

88.7%

KM 79

Different styles of change

1. Small change --- By individual effort, a better

way of proceeding a job is

considered. (Idea creation)

(KAIZEN)

2. Medium change --- By group effort, a better way

(Small group
activities)

3. Big change
(Innovation)

is proposed by following
predetermined steps (or
rule).

--- By investments in new technology

or equipment, dramatic alterations
are achieved.
2

KM 80

Tool Change

Process
Change

Tomato Juice

Newspaper
Article

Nikkei News,
Nov. 22,1997

KM 81

Hydroponics Cultivation

KM 82

6000 tomatoes

http://www.arigat.net/kandoh.html 1

Tomato Juice

KM 83

Tool Change

Process
Change

Material
Change

Input

Output
Industry

Man-power
Machines
Materials
Methods
(4Ms)

KAIZEN
action
2

Two Attitudes

Management

KM 84

Breakthrough

Staff
Floor people

Status quo

KM 85

Japanese firms
Management
Staff

a
v
o
n
In

n
it o

N
E
Z

tu
a
St

Floor people

o
u
q

Non-Japanese firms
Management
Staff
Floor people

ti o

a
v
N
o
E
n
IZ
In
A
K

us
t
a
St

o
u
q

KM 86

Fin