Kaizen
Week09
Elements of TQM
Employee
empowerm
ent
Continuou
Team s
approach improveme
nt
Competitiv
e
Champion
benchmark
ing
TQM
Long term
Knowledge relationshi
of tools p with
supplier
Decision
based on
Quality at
facts rather
the source
than
opinions
Kaizen CONCEPT of LEAN:
Continuous Improvement
Kaizen is a Japanese concept which involves continuous improvement of day to
day activity.
Kaizen means “Change for Good” or “Change is Good”
Normally known kaizen as “Continuous Improvement”
Starting point for improvement is to recognize the need. This comes from
recognition of a problem. If no problem is recognized, there is no recognition of
the need of improvement.
Kaizen objective: Reduce Waste & Improve
Productivity
Main features of Kaizen
Why Kaizen is required?
Principles of Kaizen
Principles of Kaizen
Principles of Kaizen
Principles of Kaizen
Principles of Kaizen
Types of Kaizen
Point Kaizen: Point kaizen is one of the most commonly implemented types of
kaizen. This is a very quick approach that can be implemented without much
planning.
Line Kaizen: Line kaizen is usually referred to as the spreading of lean from
the point. That is, it refers to utilize lean techniques in both streams of the
organization, and forming a line between the two.
System Kaizen: System kaizen is to address system level problems in an
organization. It is one of the upper level strategic planning methods. It is used
to develop a vision for the whole organization’s future state, leveraging
concepts like value stream maps that will result in some planned kaizen events
over a long period.
Plane Kaizen: It is the next upper level of line kaizen. It is usually called value
streams that are several lines connected together. One can see that changes or
improvements made to one line gets implemented to other lines or processes
present in the plane.
Phases of Kaizen
Identify the problem
Collect the facts
Analyze the system
Develop a appropriate solution
Implement the solution
Verify the Implementation
Process
Difference between Kaizen and
Innovation
Kaizen: small improvements as a result of continuous effort covering all areas
and all employees
Innovation: Involves a drastic improvement as a result of large investment in
new equipment or new technology.
Pillars of Kaizen
1. Housekeeping: A process of managing Gemba
(workplace) for continuous improvement.
For proper housekeeping, the 5S framework is used.
Pillars of Kaizen
2. Waste Elimination: Any non-value-adding resource is
classified as Muda (waste).
7 waste of Lean Management:
5 Principles of waste elimination:
Pillars of Kaizen
3. Standardization: Standardization is the practice of setting, communicating,
following and improving standards and standard work.
Benefits
Reducing waste
Simplifying work processes
Improving safety
Improving employee and customer satisfaction
Space saving
Cost reduction
Productivity and quality improvement
Making a process error proof
Kaizen Sheet
Kaizen Examples:
