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