KYZEN

(or Kaizan)
Continual I mprovement
beyond
Business Excellence

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KYZEN MEANS ..
CONTINUING IMPROVEMENT
in
PERSONAL LIFE
HOME LIFE
SOCIAL LIFE
WORKING LIFE
5/25/2014 Palma Academy Amman Jordan 2

KYZEN
AT WORKPLACE
MEANS ..
CONTI NUAL ONGOI NG I MPROVEMENT
I NVOLVI NG EVERYONE
Top management
Managers
Workers, alike
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KYZEN.. WHY ?
Todays Business Environment & Challenges
include :
Costs of: material, energy, labor and services
Overcapacity of production facilities
Increased marketplace competition, in saturated or
dwindling markets
Changing consumer values and more exacting quality
requirements
Need to introduce new products more rapidly
Need to lower the breakeven point

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KYZEN
Is ..

Customer-driven strategy for improvement and
ensures all activities eventually lead
to
increased Customer Satisfaction
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KYZEN emphasis and
generates ..

Process- oriented way of Thinking,and a
Management System
that supports and acknowledges
Peoples Process - oriented efforts
for
Continual Improvement
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KYZEN Philosophy:

Our way of life (working /social / home)
deserves to be
Constantly Improved
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What is Improvement ?


IMPROVEMENT
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Kyzen
Small & incremental
improvements in the status quo
as a result of ongoing efforts
( process oriented )
I nnovation
Drastic improvement in the
status quo as a result of a large
investment in a new technology /
equipment
Top Management

Middle Management

Supervisors

Workers

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INNOVATION
Maintenance
KYZEN
THE KYZEN CONCEPT
Top Management

Middle Management

Supervisors

Workers
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I NNOVATI ON
MAI NTENANCE
THE INNOVATION CONCEPT
THE KYZEN INVOLVEMENT ..
TOP MANAGEMENT
Be determined to introduce KY'ZEN as a corporate
strategy
Provide support & direction for KYZEN by allocating
adequate resources
Establish policy for KYZEN & cross- functional goals
Realize KYZEN goals through policy deployment &
audits
Build systems, procedures, & structures conducive to
KYZEN
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THE KYZEN INVOLVEMENT
MIDDLE MANAGEMENT AND STAFF ..

Deploy and implement KYZEN goals as directed by top
management through policy deployment and cross-
functional management
Use KYZEN in functional capabilities
Establish, maintain, and upgrade standards
Make employees KYZEN conscious through intensive
training programs
Help employees develop skills and tools for problems
solving
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THE KYZEN INVOLVEMENT..
SUPERVISORS
Use KYZEN in functional roles
Formulate plans for KYZEN and provide guidance to
workers
I mprove communication with workers and sustain high
morale
Support small group activities(such as quality circles)and
the individual suggestion system
I ntroduce discipline in the work place
Provide KYZEN suggestions
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The five main elements of kaizen
Teamwork
Personal discipline
Improved morale
Quality circles
Suggestions for improvement

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THE KYZEN INVOLVEMENT ..
WORKERS
Engage in KYZEN through the suggestion system and
small group activities
Practical discipline in the work shop
Engage in continuous self development to become
better problem solvers
Enhance skill and job performance expertise with cross
education
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PLAN
DO
CHECK
WHAT
ACTION
WHY
HOW Planning Countermeasure
Analysis of Problem
Standardization
Identification of Causes
Implementation
Confirmation of result
Definition of Problem
THE KYZEN ROUTE
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Abrupt and volatile Gradual and constant CHANGE 4
Intermittent and non
incremental
Continuous and
incremental
TIME
FRAME
3
Big steps Small steps PACE 2
Short term but
dramatic
Long term & long
lasting but undramatic
EFFECT 1
INNOVATION KYZEN
KYZEN & INNOVATION
A Featuristic Comparison
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Technological break-
throughs , new
inventions ,new
theories
Conventional know-
how and state of art
SPARK
8
Scrap and rebuild Maintenance and
improvement
MODE
7
Rugged individualism
Individual ideas and
efforts
Collectivism, group
efforts, systems
approach
APPROACH
6
Select few
champions
Every body INVOLVE-
MENT
5
INNOVATION KYZEN
KYZEN & INNOVATION
A Featuristic comparison
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Better suited to fast
growth economy
Works well in slow-
growth economy
ADVANTAGE 12
Results for profits Process and efforts
for better results
EVALUATION
CRITERIA
11
Technology People EFFORT
ORIENTA-
TION
10
Requires large
investments but little
effort to maintain it
Requires little
investment but great
effort to maintain it
PRACTICAL
REQUIRE-
MENTS
9
INNOVATION KYZEN
KYZEN & INNOVATION
A Featuristic comparison
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KYZEN vs. INNOVATION
MARKET
PRODUCTION
DESIGN
TECHNOLOGY
SCIENCE
INNOVATION
KYZEN
THE NEXT PROCESS
IS
THE CUSTOMER


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The Segmentation of KYZEN Program
Within ones own
work area
Within the same
workshop
Focus on systems
& procedures
Targets
Every body QC- circle(group)
members
Managers &
Professionals
Involves
Common sense
Seven Statistical
Tools
Seven Statistical
Tools
New Seven Tools
Seven Statistical
Tools ,New Seven
Tools,
Professional skills
Tools
Individual
oriented
KYZEN
Group
oriented
KYZEN
Management
oriented
KYZEN
Continued
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The Segmentation Of KYZEN Program
Suggestion
system
Small-group
activities
QC circle
Suggestion system
Line and staff
project team
Supporting
system
Many
Two or three per
year
As many as
management
chooses
Achieve-
ments
Any time Requires four or
five months to
complete
Last for the
duration of the
project
Cycle
(Period)
Individual
oriented
KYZEN
Group
oriented
KYZEN
Management
oriented
KYZEN
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On-the -spot
improvement
Improved work
procedure
Revision of
standard
New system and
facility
improvement

Result

Inexpensive
Mostly
expensive
Some times
requires small
investment to
implement the
decision
Impleme -
ntation
cost
Individual
oriented
KYZEN
Group
oriented
KYZEN
Management
oriented
KYZEN
The Segmentation Of KYZEN Program
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Gradual and visible
improvement


Gradual and
visible
improvement

Gradual and visible
improvement
Marked upgrading
of current status
Direction
Morale
improvement
KYZEN awareness
Self-development
Morale
improvement
Participation
Learning
experience
Improvement in
managerial
performance
Booster
Individual
oriented
KYZEN
Group
oriented
KYZEN
Management
oriented
KYZEN
The Segmentation Of KYZEN Program
KYZEN
Based Suggestion Schemes
Main subjects for a Kyzen based Suggestion System
are recommended to include :
Improvement in ones own work
Savings in energy, material, and other resources
Improvement in working environment
Improvement in machines and processes
Improvement in jigs and tools
Improvement in office work
Improvement in product quality
Ideas for new product
Customer services and customer relations
Others

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I mplement the change, if :
Managers are willing to go along with a change if it
contributes to any one of the following goals:
Making the jobs easier
Removing drudgery from the job
Removing nuisance from the job
Making the job safer
Making the job more productive
I mproving product quality
Saving time and cost
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I f Humans will not be improved,
genetically,
Robots will take over.

( EURO NEWS )
29th January 2002
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KYZEN
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THANK YOU