What is kaizen?

Kaizen is a Japanese term meaning "Continuous Improvement".

Kaizen is

• Philosophical Approach
• Common Sense Approach

There are two essential elements that make up KAIZEN:

* improvement/change for the better; and

* ongoing/continuity.

Introduction to Kaizen (Different thoughts)

---Kaizen is continuous improvement
------Kaizen is employee involvement
---------Kaizen requires a cultural change

The purpose of Kaizen is to improve the quality continuously by eliminating wastes in

terms of time, money, rework, etc. It involves everyone from Manager level to worker
level. The key aspect of KAIZEN is that it is an on-going, never-ending improvement
process.

"KAIZEN means improvement. Moreover, KAIZEN means continuing improvement in

personal life, home life, social life, and working life. When applied to the workplace,
KAIZEN means continuing improvement involving everyone - managers and workers
alike". KAIZEN recognizes that improvements can be small or large. Many small
improvements can make a big change.

People at all levels of an organization can participate in kaizen, from the CEO down, it is
best if everyone is involved. The format for kaizen can be individual, suggestion system,
small group, or large group.
Kaizen is a daily activity where the purpose goes beyond easy productivity
improvements. It is also a process that, when done correctly, cultivates the workplace,
eliminates hard work and teaches people how to carry out a new way of thinking about
there job by using new methods and showing them how to learn to see and eliminate
waste.
KAIZEN is thus a (relatively) low cost, simple, team-based approach. Team are trained in
the techniques and tools of KAIZEN. They then brainstorm improvement ideas and vote
on them for priority action.
They then create an action/implementation plan which is submitted to management for
approval.
Assuming it is approved, the team then sets about implementation (with professional help
if appropriate). The team then meets weekly to review progress, identify/overcome
barriers, celebrate successes, and document the resulting changed processes.

Kaizen has three main principles

• Consider the process and the results!

• The need to look at the entire process of the job at hand and to evaluate the job as to the
best way to get the job done.
• Kaizen must be approached in such a way that no one is blamed and that the best
process is put into place.

Kaizen is only one of many ways to create a good place and also an effect place for the
company to make money and have less wasted time.5S it is a very effective Japanese
program and together Kaizen and 5S are very effective when used correctly to create a
safe and effective work place.

5S
5S is a technique for organizing a workplace, especially a shared workplace like a shop
floor or an office space. It's sometimes referred to as a housekeeping method but this
description can be misleading because organizing a workplace goes beyond
housekeeping. The key targets of 5S are workplace morale and efficiency. The point of
5S is, to assign everything a location, time is not wasted by looking for items. It is
quickly apparent when something is missing from its designated location. 5S advocates
believe the benefits of this style comes from deciding what should be kept, where it
should be kept, and how it should be stored.

A very important part of 5S and "standardized cleanup" is Seiton. The key concept here is
to order items or activities in a manner to promote work flow. For example, tools should
be kept at the point of use, workers should not have to repetitively bend to access
materials, and flow paths can be altered to improve efficiency.
A term commonly used in Japan is gemba kaizen. It is an expression that conveys
commitment to continuous improvement of practices and processes as a business
philosophy. Translated to English "gemba" means shop floor and "kaizen" means
continuous improvement. This certificate prepares students/workers to actively
participate in implementing ongoing, world-class manufacturing activities necessary to
keep their company globally competitive now and into the future.
One of the more attractive features of gemba kaizen as a management philosophy is its
independence from technology, complex procedures, or equipment, because gemba
kaizen techniques focus on techniques like total quality management, just-in-time, total
product maintenance, and visual management to deliver maximum quality. For some
companies, gemba kaizen has become a leading philosophy for implementing "lean
thinking" into their processes and products. The result has been elimination of waste (in
terms of materials, effort, money, time, etc.) and an improvement in fiscal performance.
Not surprisingly, gemba kaizen's approaches to eliminating waste are also one of the
easiest and least costly steps to take in improving environmental performance.
In Japanese, the definition of Kaizen is "improvement" and particularly, "Continuous
Improvement"-- slow, incremental but constant.

Different styles of change

1. Small change (KAIZEN)

By individual effort, a better way of preceding a job is considered. (Idea creation)

2. Medium change (Small group activities)

By group effort, a better way is proposed by following predetermined steps

(or rule).

3. Big change (Innovation)

By investments in new technology or equipment, dramatic

Large-Scale Vs. Small-Scale Improvement

Large scale improvement is attractive. It promises quantum jumps in productivity, quality

and effectiveness. However, it is difficult to implement because it affects many areas,
people and processes. The design must be near-perfect because failure courts disaster.
The risks and difficulties work against large-scale improvements.

Small-scale improvements are easier and faster. The risks are low because they generally
have limited effect. However, the accumulated effect is often greater than a single large
improvement.

Here is the sequence of events for a Quick & Easy Kaizen

1. An employee identifies a problem, waste, defect or something not working.
He/she writes it down.
2. Employee later develops an improvement idea and goes to immediate supervisor.
3. Supervisor reviews it and encourages immediate action.
4. The idea is implemented.
5. The idea is written up on a simple form in less than three minutes.
6. Supervisor posts the form to stimulate others and recognize the accomplishment.

Quick and Easy Kaizen Benefits

Mini kaizen empowers employees, enriches the work experience and brings out the best
in every person. It Improves quality, safety, cost structures, environments, throughput and
customer service.

Quick and Easy Kaizen (or Mini-Kaizen) is aimed at increasing productivity, quality,
and worker satisfaction, all from a very grassroots level. Every company employee is
encouraged to come up with ideas – however small – that could improve his/her
particular job activity, job environment or any company process for that matter. The
employees are also encouraged to implement their ideas as small changes can be done by
the worker him or herself with very little investment of time.
Quick and easy Kaizen helps eliminate or reduce wastes, promotes personal growth of
employees and the company, provides guidance for employees, and serves as a barometer
of leadership. Each kaizen may be small, but the cumulative effect is tremendous.

Kaizen Activities for Increased Profits

Four Measures for Increased Profits

When companies aim to improve their profits, the following four methods are effective:

1. Raise unit prices for the sales of goods and services

2. Lower unit prices for the purchase of materials: input
3. Increase the amount of output
4. Produce goods and services with lower costs through Kaizen activities
The first method, raising unit sales prices, often brings many difficulties. This is because
products on the market are already priced at their market prices, and the consumers will
buy products and services from the competition if unit sales prices are raised. It is clear
that a price increase will result in a loss of a certain share of the market. Other than the
cases where the product enjoys a company monopoly of the market, or there is some
understandable motivation such as the oil shock, it is difficult to carry out price increases.

The second method, lowering the purchase prices of materials, will earn charges of
difficulty from those in charge of purchasing because they are always putting great effort
into buying materials as cheaply as possible.

The third method, increasing the amount of output by increasing men and facilities, is
indeed a good idea. If the goods and services are bought by consumers, the company
profits will increase. However, if surplus output remain as stock, or are disposed of as
waste, profits will not increase. Losses requiring extra materials or manpower will result
instead.

The Effects of Kaizen Activities

The most practical measures for improving profits, which are carried out successfully in
many companies, are found in the fourth method, Kaizen activities. Not all Kaizen
activities can bring about cost reductions, but in many cases, cost-cutting is achieved if
the activities target the elimination of waste. It is true that among those four measures, the
economic effects of Kaizen activities are comparatively small when compared to the
other three measures. Kaizen activities are characterized as: little and many makes a pile.

Who has the best knowledge to reduce costs?

Standard Costing

Managers and engineers develop Standards.

Kaizen Costing

Workers are closest to the process and thus know best.

kaizen is a Japanese tradition which is now used internationally, modified by each culture
to best suit their own business environments. A literal translation of kaizen could be "to
become good through change". At its most basic the concept of kaizen is one of
restructuring and organizing every aspect of a system to ensure it remains at peak
efficiency.
 Kaizen is founded upon five primary elements:

Quality Circles: Groups which meet to discuss quality levels concerning all aspects
……of a company's running.

Improved Morale: Strong morale amongst the workforce is a crucial step to …....
achieving long-term efficiency and productivity, and kaizen sets it as a ……
foundational task to keep constant contact with employee morale.

Teamwork: A strong company is a company that pulls together every step of the
…….way. Kaizen aims to help employees and management look at themselves as …….
members of a team, rather than competitors.

Personal Discipline: A team cannot succeed without each member of the team …
….being strong in themselves. A commitment to personal discipline by each …….
employee ensures that the team will remain strong.

Suggestions for Improvement: By requesting feedback from each member of the

…… .team, the management ensures that all problems are looked at and addressed …
…..before they become significant.

Continuous improvement implemented

for building a world-class Pakistan
In this world no one is perfect there is always room for improvement but in our country
there is a lot of thing that needs attention or improvement.

KAIZEN's approach to project management lends itself to a high degree of

responsiveness. Operations allow us to expedite decision making, and to respond quickly
to challenges and opportunities as they arise.

Kaizen implementations:

If Daewoo Pakistan or any other transport company is using Kaizen then they are more
favorite in the eye of traveler. We are here implementing Kaizen 5S model on Daewoo
Pakistan.
Kaizen steps which the Daewoo must use

Eliminate:

Daewoo must try to eliminate the problems which causing problems to their customers.

Reduce:

Reducing involves some of steps to reduce problem hindering to the quality service.

Change:

Daewoo comes with continues change in Pakistan road transport industry and to change the
journey standard of people.

5S of Kaizen:

Daewoo Pakistan is fulfilling their promises by providing quality services to customers. Daewoo
must be use 5s approach to maintain their quality.

Sei-ri (Organization)

Separating: Refers to the practice of going through all the tools, materials, in the work
area and keeping only essential items. So the Daewoo must be separate their terminal
according to the requirements or demand of the customers because there is a lot of crowd
on the terminal. They must be separate terminal root wise divided in to parts.

Sei-ton (Neatness)

Sorting: Focuses on the need for an orderly workplace. Orderly in this sense means
arranging the bus service tools and passengers luggage in an order that promotes
traveling. It’s very important that each step has been done the correct place at the correct
time. Daewoo must make sure that each and every employee must follow the company
rules and regulations.

Sei-so (Cleaning)

Shine: To keep the BUSES or terminal clean as well as neat. Cleaning is a daily activity.
At the end of each shift, the work area is cleaned up and everything is restored to its
place.
Sei-ke-tsu (Standardization)

Standardizing: This refers to standardize your terminals and buses. It refers to more than
standardized cleanliness this means operating in a consistent and standardized fashion.
Everyone knows exactly what his or her responsibilities are. Daewoo must have some of
play lands at terminals for children. As well as Daewoo must think how to provide
entertainment to the children during journey. Some of customer’s complaints about that
Daewoo some times not provide the fresh food. So Daewoo make sure to make happy the
angered customers.

Shi-tsu-ke (Self-discipline)

Sustaining: Refers to maintaining standards. Once the previous 4S's have been
established they become the new way to operate. Maintain the focus on this new way of
operating, and do not allow a gradual decline back to the old ways of operating.
These are "Sort, Straighten, Shine, Systemize and Sustain". "Standardize" is also used as
an alternative for "Systemize". Sometimes "Safety" is included as 6th S it’s very
important in our country like Pakistan to provide security to passengers.

4R’s of improvements which are very important in Daewoo:

1) Repair
2) Refinement
3) Renovation
4) Reinvention

Apply kaizen on the Pakistan railway

If we want to see our railway system in standardize form then we must implement kaizen
in our railway. I am going to discuss some major areas that needs proper attention.

Setting up internal repair workshops

---Toilet vacuum unit overhaul
---Catering overhaul
---Bogie overhaul
---Painting repair
Planning and review
There must be planning and reviewing departments. All the work done through proper
planning, there is a two type of planning, fleet planning and depot planning which one
can easily see or understand with the help of these pictures……

Fleet planning Depot Planning

KAIZEN in Just-In-Time system

Improvement is everyone's job.

Think of ways to make ideas work.
Don’t say .can’t.
Don’t substitute money for brains.
Ask Why? Five times.
Improvement is not made from a conference room.
More ideas are better, especially from people close to the problem.
Follow up to make sure the idea is working.
Improvement is endless.

Bogie overhaul program

1 train after every 9 days must be

--Tested
--Bogie overhaul

Kaizen Promotion Office

There is need of kaizen promotion offices. The work of these offices is to check, which
areas require improvement. Like….
  Kaizen promotion offices set up
 Full time and part time staff

They are working on…..

 Distances reduced
 Task times reduced
 Space for bogie overhaul
 Work arising task times reduced
 Health and Safety risks reduced

Setting up the Kaizen Promotion Office in pakistan railway

Traits that must be in Good Team Leaders

---Has experienced a kaizen event
---Good knowledge of lean manufacturing (if production area event)
---Good knowledge of waste elimination techniques
---Not dictatorial - understands participative management
---Comfortable working in the target area
---Good people skills

Kaizen Event Sequence (Start to Finish)

1. Training & kick-off activities
Tools of continuous improvement (pareto, fishbone, run charts, 5-whys,
process analysis, etc.)
2. Analysis of current “state”
3. Select areas of focus
4. Create possible solutions
5. Select solutions
6. Establish metrics for success
7. Plan & implement (repeat if necessary)
8. Standardize and sustain Paves the way for future events
9. Report results
10. Celebrate
Our government Offices needs Improvement
With the passing of time this dirt is gone our habits or good to say our need and we did
not want to change the things or to see our environment clean and some time I think that
we are feeling proud to see the polluted environment, may be behind that some of the
reasons or truths that we did not want to listen like eat dirt, fling dirt, dirty soils, dirty
work and last but not least is laziness and ignore our duties but these moral offences or
sins are not the GOD gifted. These evils come in our soils due to our dirty thinking or
may be discovery of mind.
Reason behind to discuss these problems, is to improve the things around us or to come
with positive continues change in our daily life or professional life due to this one day we
are proud of our-self. Start with small continues changes or improvements one day these
small improvements convert into big change. For the purpose of this Japanese use kaizen,
kaizen is not just for Japanese we can also use according to our environment…like….
“Improvements in small steps”

A Japanese term for making improvements to a process through small, incremental

amounts rather than through large innovations.

Before 5S After 5s

• The primary focus of 5S is the elimination of wastes in the work environment that
result from unorganized, unclean material, tools, machines, desks, inventories,
aisles, walkways, storage locations.
• To eliminate the wastes that result from” uncontrolled” processes.
• To gain control on equipment, material & placement and position.
• Apply Control Techniques to Eliminate Erosion of Improvements.
• Standardize Improvements for Maintenance of Critical Process Parameters.
The way that must be use for packing orange,
Apple or other fruits

The strategy behind that is…..

Orange Packing (1)

It is difficult to open net and put oranges in the net at the same time.

Productivity: 1 net per min.

Orange Packing (2)
Cooperation increases work efficiency.

Productivity: 5 nets per min.

A selection of better means or a change of current method for

achieving an objective

Productivity: 10 nets per min.

When served a glass of water to someone

These are some of the basic improvements that we needs

Placed the glass strongly on the table

Hold the glass with care.
Place the glass with care.
Treat customers from your heart.
Change the way of holding the glass
Hold the bottom of the glass.
Support the glass with a little finger.
Suggestion System
Propose improvement ideas for any activity in the company.
Suggest your ideas, and examine them and implement some of these ideas later.

Suggestion System Concept

The suggestion system is an integral part of an established management system that
aims at involving employees in Kaizen. The number of worker's suggestions is regarded
as an important criteria in reviewing the performance of the worker's supervisor and the
manager of the supervisor.
management encourages employees to generate a great number of suggestions and
works hard to consider and implement these suggestions, often incorporating them into
the overall Kaizen strategy. Management also gives due recognition to employee's
efforts for improvement. An important aspect of the suggestion system is that each
suggestion, once implemented, leads to an upgraded standard.
Quality control (QC) circles can be viewed as a group-oriented
suggestion system for making improvements. QC circle is a
small group that voluntarily performs quality-control activities
in the workplace.
Total quality control (TQC) involves everyone in the organization and is aimed at
improvement of managerial performance at all levels.
KAIZEN System
Propose only improvement ideas which will improve your own work.

KAIZEN
sheet

Suggestion System
Workers.
Responsibility Management responsibility

Workers. responsibility Management

responsibilit