Kaizen
Kaizen means change (kai) to become good (zen). There are many versions of Kaizen where different additional components have been added to the framework. Here is a basic description, based on the book Key Management Models, without any of the additions. Kaizen can be used to solve types of problems: process inefficiencies, quality problems, large inventories and delivery and lead-time problems. Correct implementation of the Kaizen concept will lead to improved productivity, quality, better safety, faster delivery, lower costs, greater customer satisfaction and improved employee morale and job satisfaction.
Kaizen focuses on 3 different steps. First step is to eliminate muda (waste and inefficiencies), After the reduction of waste, good housekeeping based on the 5-S framework is necessary. Finally, standardization of practices for good housekeeping.
Elimination of muda (waste and inefficiencies). The types of waste are:
Defective products (defects in quality prevents customers from accepting the manufactured product. The effort to create these defects is wasted). See Six Sigma section on this web page.
Over-production (ever production is the production or acquisition of items before they are actually required. It is the company’s most dangerous waste because it hides production problems.)
Transportation (each time a product is moved it runs the risk of being damaged, lost, delayed, etc., as well as being a cost with no added value.
Waiting (refers to the time spent by workers waiting for resources to arrive as well as the capital sunk into good and services that have not yet been delivered to the customer.
Excess inventory (whether in the form of raw material, work-in-progress, of finished goods, excess inventory represents a capital outlay that has not yet produced an income for either the producer of the consumer. If any of these three items are not being processed actively to add value, it is waste.)
Motion (in contrast to transportation, motion, refers to the worker or equipment, and is represented be damage, wear and safety.)
Extra processing (using a more expensive of otherwise valuable resource than is required for the task, or adding features that are included in the products but are not needed by the customer.
Good housekeeping based on the 5-S framework
Seiri- tidiness. Separate what is necessary for the work from what is not. This should help to simplify the work.
Seiton – oderliness. You can increase efficiency by making deliberate decisions regarding the allocation of material, equipment, files, etc.
Seiso – cleanliness. Everyone should help to keep things clean, organized and looking neat and attractive.
Seiketsu – standardized clean-up. The regularity and institutionalization of keeping things clean and organized as part of visual management, is an effective means of continuous improvement.
Shitsuke – discipline. Personal responsibility for living up to the other four Ss can make or break the success of housekeeping.
Standardization
Standardization of practices and institutionalization of the 5-Ss will make it easier for everyone in the organization, including newcomers, to improve continuously. Top management plays an important role in guarding and acting for widespread implementation and co-ordination of Kaizen, the 5S method and standardization. Another important part in Kaizen is to encourage employees to come up with suggestions during weekly meetings (Kaizen events) for small and large improvements.
Kaizen focuses on 3 different steps. First step is to eliminate muda (waste and inefficiencies), After the reduction of waste, good housekeeping based on the 5-S framework is necessary. Finally, standardization of practices for good housekeeping.
Elimination of muda (waste and inefficiencies). The types of waste are:
Defective products (defects in quality prevents customers from accepting the manufactured product. The effort to create these defects is wasted). See Six Sigma section on this web page.
Over-production (ever production is the production or acquisition of items before they are actually required. It is the company’s most dangerous waste because it hides production problems.)
Transportation (each time a product is moved it runs the risk of being damaged, lost, delayed, etc., as well as being a cost with no added value.
Waiting (refers to the time spent by workers waiting for resources to arrive as well as the capital sunk into good and services that have not yet been delivered to the customer.
Excess inventory (whether in the form of raw material, work-in-progress, of finished goods, excess inventory represents a capital outlay that has not yet produced an income for either the producer of the consumer. If any of these three items are not being processed actively to add value, it is waste.)
Motion (in contrast to transportation, motion, refers to the worker or equipment, and is represented be damage, wear and safety.)
Extra processing (using a more expensive of otherwise valuable resource than is required for the task, or adding features that are included in the products but are not needed by the customer.
Good housekeeping based on the 5-S framework
Seiri- tidiness. Separate what is necessary for the work from what is not. This should help to simplify the work.
Seiton – oderliness. You can increase efficiency by making deliberate decisions regarding the allocation of material, equipment, files, etc.
Seiso – cleanliness. Everyone should help to keep things clean, organized and looking neat and attractive.
Seiketsu – standardized clean-up. The regularity and institutionalization of keeping things clean and organized as part of visual management, is an effective means of continuous improvement.
Shitsuke – discipline. Personal responsibility for living up to the other four Ss can make or break the success of housekeeping.
Standardization
Standardization of practices and institutionalization of the 5-Ss will make it easier for everyone in the organization, including newcomers, to improve continuously. Top management plays an important role in guarding and acting for widespread implementation and co-ordination of Kaizen, the 5S method and standardization. Another important part in Kaizen is to encourage employees to come up with suggestions during weekly meetings (Kaizen events) for small and large improvements.
Source: Michael V. Marm, Eric V. Roegner, Craig C. Zawada, The Price Advantage, 2004, New Jersey (link to latest edition)
