What is kaizen?

Definition of kaizen

•改 (Kai): Change, reform, ለውጥ ለመልካም

• 善 (Zen): Good, right, virtue
• KAIZEN means “Change for the Better.”
 What is kaizen Contnd …

“The KAIZEN philosophy assumes

that–be it our working life, our social
life, our home life, our way of life-
deserves to be constantly improved”

Masaaki Imai
 What is kaizen Contnd…

“It is a unifying thread running through

the philosophy, the systems, and
problem solving tools developed in
Japan over the last 30 years”.

Masaaki Imai
 What is kaizen Contnd…

• KAIZEN can be built in and run with an

integrated and company-wide approach
through the collaboration of all the
levels of the organisation that are top
management, middle managers and
front-line employees.
 What is kaizen Contnd…

• KAIZEN is a philosophy of continuous

undertaking by an organization to
improve its activities and processes with
the goal to always improve quality of
products and services so that the
organisation can meet full customer
satisfaction.
 What is kaizen Contnd…

• Commitment , genuine participation and

motivation of all the three actors are
critical factors.

• KAIZEN normally places the foremost

importance in improvements at the front-
line workplaces as the foundation of all
the improvement efforts.
 What is kaizen Contnd…

• KAIZEN encompasses all the areas that

are related to quality, productivity, cost,
delivery, safety and moral whose
simultaneous improvements are
essential in achieving customer
satisfaction and success of the
organisation.
 What is kaizen Contnd…

• KAIZEN is a dynamic activity in revolving

cycles of PDCA, (Plan, Do, Check and Action).
 What is kaizen Contnd…

ማስተካከል ማቀድ

ማረጋገጥ መተግበር
 What is kaizen Contnd…

• Once a new improvement becomes a new

standard, the next cycle is set up to seek
further improvement.

KAIZEN is a continuous challenge towards

ever higher-level improvement, cycle by
cycle, without an end.
 Kaizen Ultimate Goals
Goals
Stronger customer focus
Added Value
Stronger
Secure places of work customer focus
Guarantee
D Q Improve quality
Competitive capacity Delivery

Growth
Reliable, capable
Improved
equipment &
logistics
C process
Decrease cost
 Characteristics of KAIZEN
1. Continuity
2. Participatory approach
3. Accumulation of small improvements
4. Improvement without a large amount of
investment
1. “Continuity”
 2. “Participatory approach”
Promotion organization

Division 1 Division 2 Division 3 Cross functional

organization
QCC 1
QCC 2
QCC 3

QCC 1

QCC 2

QCC 1
QCC 2
 3.“Accumulation of small
improvements”

• KAIZEN does not aim to attain significant

result, but accumulation of small
improvement leading to significant
result.
4. “Improvement without a large amount
of money”
• Waste elimination may not require
investment or little investment.

• Introduction of 5S for a starter of KAIZEN

may need only a little investment.
 Question

Left figure is a Roman

number 9
Add 1 line to make it 6
 Answer

• Straight line and curve

（ 1×6 ） line can be considered as
a line.
（ SIX) • Number 6 and S can be
done by a line

When a specific condition exist, it is necessary to

start from examining the characteristic of the
condition itself first.
 Kaizen tools
• These are kaizen implementation methods and
technical tools. By basing on kaizen philosophy
and through following kaizen systems , these tools
can bring continuous improvement. For example,
 5s
 7 Mudas /wastes
 Qc 7 Tools (check sheet, pare to, histogram, fish bone,
graph,etc..)
 JIT (just in time production)
 Basics of Industrial Engineering(IE)
 Any other analytical tools
 Introduction to 5S
• How mess occurs at workplace?

Unnecessary
Necessary Not necessary now,
but maybe in the
future
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 5S Benefits to YOU
• It will make your workplace a safer, cleaner
and more enjoyable/ pleasant place to work
• Make your job more satisfying.
• Eliminate overburdens and disappointment.
• Make it easier to communicate with everyone
you work with
• Gives you an opportunity to give creative
input how your work place should be
5S Benefits to Organization

• Zero defects brings higher quality

• Zero waste brings reduced cost
• Zero delay brings reliable delivery
• Zero accident increase safety
• Zero breakdown, increase productivity
• Zero complaint brings greater confidence and trust
 What is 5S ?
• Sort Seiri

Set-In-Order Seiton

Shine Seisou
Standardize Seiketsu

Sustain Shitsuke
 1. Sort
 Remove all items from the workplace that are not
needed for current production or administrative
operation.
 Keep“only what is needed, only in the
amount needed, and only when it is
needed”.
Red Tag Discard

No Tag
Keep it
 Why Sort is important?

 Space, time, money,

energy and other
resources can be managed
and used most effectively
 Problems in the work
flow are reduced.
 Communication between
employees is improved.
 Product quality and
Productivity is enhanced
 2. Set-In-Order
• Arranging needed items in the way easy to use and
labeling them so that easy to find and put
away(visual management)
 Set in order
 Arrange needed items so;
 it is easy to use.
 label them so that anyone can find them easily and put them
again.
 Set-in-order is important because it eliminates;
 Time spent searching for an item
 Motion wastes
 Difficulty returning item to its original place
 Excess inventory
 Reduce damage
 safety
Set in order
3. Shine
 What is Shine ?
Shine means keep everything clean.

When we Shine, we can’t avoid

inspecting the item at the same time.
Therefore Shine and Inspect come
together.
 Benefits from Shine
Clean and comfortable workplace.
Increase visibility to defects when it occurs.
Helps to maintain safer workplace.
Good working environment increase morale.
Early detection of machinery and equipment
failure.
4. Standardize
 What is Standardize?
Standardize is the method you use to maintain
the first three pillars (Sort, Set in order and
Shine)
Make it a rule to perform given work in the
given manner.
Standardize is different from the first three
pillars because it is a method used to sustain
the first three pillars rather than housekeeping
activity.
 Benefits from Standardize
 The basic purposes are to;
1. Lead to workplace standardization
 prevent setbacks in the first three pillars
 Make implementing them a daily habit
 Ensure that all the three pillars are maintained in their
fully implemented state.
2. Lead to work standardization
 Muda elimination
 Quality improvements
 Cost reduction
 Delivery time improvements
 Process improvements
 5. Sustain

• Means making a habit of properly

maintaining correct procedures
 Some techniques to sustain
5S Slogan
5S poster
5S newsletter and kaizen board
5S audit
awarding systems
Big cleaning day
5S month
Benchmarking tour
 Use Slogan and Poster of 5S Activity
• It encourage all the participants.
＜ Samples of slogan ＞
• “Refresh yourself and workplaces by 5S activity.”

• “Let's maintain current 5S activity and KAIZEN for

tomorrow”

• “We polish “Our Minds” as well us our factories”

＜ Sample of poster ＞
 Awarding System
awarding for 5S promotion results according to
evaluation is recommended.
• Awards may be
- For Good performance
- Award for efforts
- Award for good Ideas
• Prize winner - Group
- Individual