KAIZEN

PREPARED BY: AKSHAY PAL

(14302)
 Kaizen means improvement. Moreover it
means continuing improvement in
domestic life and working life.
 Kaizen means continuing improvement
involving everyone - from top management
to managers and workers, when it is
practiced at workplace.
 KAIZEN

 Kaizen is a Japanese quality improvement philosophy

named after the phrase “continuous improvement.”
Kaizen aims to create a quality oriented culture that
permeates all levels of the business from
manufacturing to management and aims to improve
the organization in small increments from the ground
up.

Kaizen is the father of many quality improvement

procedures including: suggestion systems, automation,
small group activities, Kanban, just-in-time, zero
defects, total productive maintenance, total quality
control, and more.
 According to Kaizen management has two
major components:
1.maintenance
2.improvement
Kaizen and innovation complement each other.
 In business Kaizen includes quality control,
automation, workers suggestion systems, just-in-
time delivery systems and the 5S process.
 And promoting a sense of pride in workers in
their work and being owners of their
responsibility.
 Kaizen involves bottom-up decision-making and
practices an employee-driven management style
that heavily emphasizes teamwork.
 The 5S techniques are fundamental techniques
which allow the increase of efficiency and
productivity while ensuring a pleasant
organizational climate.
 SEIRI – Sorting – making the difference
between necessary and useless things in
GEMBA, giving up the useless ones.
 SEITON – Ordering/Arrangement – the
ordering of all the items after SEIRI.
 SEISO – Cleaning and disturbance detection –
the working areas/equipments will be clean.
 SEIKETSU - Standardizing– the extension
of the cleaning concept to each individual
alongside with the continuous practice of
the three steps 3S.
 SHITSUKE – Disciplining – getting self-
discipline and getting used to be each
involved in the 5S actions through standard
application.
Kaizen’s Seven Deadly Wastes
 1.Overproduction – Production more than
production schedule
 2.Waiting – Poor balance of work; operator
attention time
 3.Transportation – Long moves; re-
stacking; pick up/put down
 4.Processing – Protecting parts for
transport to another process
 5.Inventory – Too much material ahead of
process hides problems
 6.Motion – Walking to get parts because of
space taken by high WIP.
 7.Defects – Material and labor are wasted;
capacity is lost at bottleneck
ADVANTAGES
 CUSTOMER SATISFACTION
 PROCESS CENTRED
 INCREASES EMPLOYEE’S MORAL
 REDUCE ERRORS
 PROMOTE OPENNESS
 ACKNOWLEDGE PROBEMS OPENLY
DISADVANTAGE
 REQUIRES PERMANENT CHANGE OF
MANAGEMENT SYSTEM
 DOES NOT PRODUCE REQUIRED
RESULTS
 DIFFICULT TO CONVINCE PEOPLE