Kaizen

Kaizen-2

PDCA-Two-Cycles

Kaizen (改善) is a Japanese term meaning "change for better" or "continuous improvement." It is a concept referring to business activities that continuously improve all functions and involve all employees from the CEO to the assembly line workers. Kaizen also applies to processes, such as purchasing and logistics, that cross organizational boundaries into the supply chain. It has been applied in healthcare, psychotherapy, life-coaching, government, and banking. By improving standardized activities and processes, Kaizen aims to eliminate waste (see Lean manufacturing). Kaizen was first practiced in Japanese businesses after World War II, influenced in part by American business and quality-management teachers, and most notably as part of The Toyota Way.

Principles

Kaizen is based on several key principles:

• Good processes bring good results
• Go see for yourself to grasp the current situation
• Speak with data, manage by facts
• Take action to contain and correct root causes of problems
• Work as a team
• Kaizen is everybody's business

Implementation

The implementation of Kaizen can vary between industries but generally involves identifying problems, creating solutions, and then controlling the new processes to ensure that improvements are maintained. The cycle of Kaizen activity can be defined as:

1. Standardize an operation
2. Measure the standardized operation (find cycle time and amount of in-process inventory)
3. Gauge measurements against requirements
4. Innovate to meet requirements and increase productivity
5. Standardize the new, improved operations
6. Continue cycle ad infinitum

This cycle is also known as the "PDCA" cycle, for Plan, Do, Check, Act.

Tools

Several tools can be used in the Kaizen process, including but not limited to:

• 5S (Sort, Set in order, Shine, Standardize, Sustain)
• Value Stream Mapping
• Kanban (看板)
• Root Cause Analysis

Impact

Kaizen is credited with contributing significantly to Japanese competitive success in the global market. Beyond manufacturing, its principles have been applied in various sectors, leading to improvements in efficiency, productivity, and quality.

Challenges

Implementing Kaizen can present challenges, such as resistance to change, communication barriers among departments, and sustaining improvements over time. Success often requires a cultural shift within the organization and a commitment from all levels of staff.

See Also

• Lean manufacturing
• Total Quality Management
• Six Sigma
• Toyota Production System

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