2. KAIZEN- AN INTRODUCTION
• Masaaki Imai is known as the
developer of Kaizen.
• 改 ('kai') KAI means 'change' or 'the
action to correct'.
• 善 ('zen') ZEN means 'good‘
• Kaizen is small incremental changes
made for improving productivity and
minimizing wastes
3. 3 main principals
• 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.
4. Features of Kaizen
• Widely applicable
• Highly effective and result oriented.
• A learning experience.
• Team based and cross-functional
5. Phases in Kaizen
A. Select an event.
B. Plan an event.
C. Implement an event.
D. Follow-up an event.
6. Benefits Of Kaizen
• Kaizen reduces waste - like inventory waste, time waste and workers
motion.
• Kaizen improves space utilization and product quality.
• Results in higher employee moral and job satisfaction.
• Teaches workers how to solve every day problems.
Toyota is well-known as one of the leaders in using Kaizen. In 1999 at
one U.S. plant, 7,000 Toyota employees submitted over 75,000
suggestions, of which 99% were implemented.
7. 5 ‘S’ in KAIZEN
• 5 S is a method for organizing a workplace, especially a shared
workplace (like a shop floor or an office space), and keeping it
organized.
• To take the concept of Kaizen performance to its ultimate level of
simplicity, it offered the following "5S" steps
• Sorting
8. Shorting keeping only essential items
Simplifying eliminates extra motion
Sweeping keep the workplace clean
Standardizing standardized work practices
Sustaining maintaining and reviewing
standards
9. PIT FALLS IN KAIZEN
• Resistance to change
• Lack of proper procedure to implement
• Too much suggestion may lead to confusion and time wastage
