Kaizen-The Japanese Methodology

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Kaizen-The Japanese Methodology:

Kaizen is a Japanese word.

Kaizen is the Japanese methodology used in lean manufacturing techniques.

Kaizen means good change or "Continuous Improvement" . 

Kaizen is a  method for improving processes with small but incremental changes over time.

Kaizen Benefits:

  • to eliminate waste.
  • to optimize efficiency.
  • to improve quality.
  • to empower employees.

Kaizen is a method to encourage employees to work together to make small but regular improvements in business processes.

Kaizen is a Japanese  philosophy that encourages continuous improvement by  all employees involvement.It is a long-term approach to small but incremental improvements.

5 in Kaizen or Steps in Kaizen technique:

1)Identifying problems

2)Analyzing the current process

3)Brainstorming the solutions and selecting the best solution.

4)Implementing the best solution into practice

5)Reviewing the results and Standardizing the solution as a part of ongoing processes.

ORIGIN OF KAIZEN:

Masaaki Imai is known as the "Father of Kaizen". 

Masaaki Imai wrote a book "Kaizen (Ky'zen), the key to Japan's competitive success".

This book includes 16 Kaizen management practices which are helpful for managers to implement kaizen tools and improve overall quality in processes.

Kaizen philosophy focuses on improving processes and operations and involving employees from all levels in business.

Two types of Kaizen:

1.Point Kaizen(for smaller improvements and are easy to implement.)

2.System Kaizen (for larger issues and requires careful planning and analysis).

5 KAIZEN  Lean Principles:

Create Customer Value. ...

Create Flow Efficiency. ...

Be Gemba-oriented. ...

Empower and Engage People. ...

Create Visual Standards.

5S of Kaizen concept:

5S methodology in Kaizen recognised worldwide is as-

Seiri (Sort), 

Seiton (Set in order), 

Seiso (Shine), 

Seiketsu (Standardize), and 

Shitsuke (Sustain).

4 Ps of Kaizen:

Purpose, 

Process, 

People, 

Performance.


4M Checklist:



Man, 

Machine, 

Material, and 

Method.

3 C's of Kaizen:

Concern, 

Cause, and 

Countermeasure.

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