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Kaizen for Lean manufacturing
Chap1:Kaizen Basic Education
Created on February 2011
Created by Japanese Genba Kaizen Web
http://takuminotie.com/english/

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Table of Content
1.What is Kaizen?
2. The History of Kaizen
・History and philosophy of Toyota Production System
・The Philosophy of Toyata Production
・The Kanban System
・“Automation with A Human Touch”
・Muda (Waste) Elimination
・The Mind of Toyota's manufacturing
3. The Kaizen Philosophy
4．How to proceed Kaizen?
5. Kaizen & Innovation
6. Practical Kaizen System

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1.What is Kaizen?
The general meaning of Improvement (Kaizen) is to improve a thing that is in bad condition.
The term Improvement in the manufacturing industry has the meaning of bottom
up activities are carried out mainly by the factory workers.
Summary:
The activities of improving the production are to equip modifications, new tools and work to ensure
the safety and operational efficiency of a production error proofing all over the area and to prevent
problems related to quality production.
Improvement is often described as Kaizen nowadays. When the expansion of Japanese
manufacturing plants abroad, trainers were dispatched from Japan to teach the local staff. MIT
researchers became the centre of the strength of Japanese manufacturing in the 1980s. Mari
Hiroshi as well as overseas are one of the most important manufacturing industry in Japan.
Through such result, Kaizen became the world-wide word in the world.
In order to improve current facilities, quality of the machine and productivity,
Field side’s wisdom, quality and the activity of increasing productivity are done.

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1. Production facilities that incorporate the wisdom, have a lead to others using the same
equipment.
2. By making modifications on their own to suppress large-scale investment rather
than just buying what you lack.
3. Improvement is not just working under the order of company but the characteristic of workers
changing things out of their own wisdom.
4. Employers support a lot of QC-circle activities. Moreover improvement is not finished once
but one after another, sustainability and continuity are important.
Value of improvement
Effect
Money×Time
＝
Multiply time
with money to
get the effect.
1. What is Kaizen?
Increasing the value without paying out money but using the wisdom to.

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2. The History of Kaizen
The management system of Toyata is the first to incorporate and utilize the wisdom of
the workers systematically to achieve achievements. The productivity in the
field side, changing of the work methods in order to improve the quality and the jigs are
used in any country and any era have been implemented with the immediate on-
site productivity without spending money and improve the quality.
1. Sakichi Toyoda ・・・ ‘Automation with A Human Touch’
2. Kiichiro Toyoda ・・・ Just-in-time (J.I.T)
3. Taiichi Ohno ・・・ Systemization of the production of Toyata
Toyata is the first to incorporate and utilize the wisdom of the workers
systematically to achieve achievements.

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Reference 1.History and philosophy of Toyota Production System
Sakichi Toyoda
‘Automation with A Human
Touch’
“Machine stops itself when a
problem occurs”
Install a device to stop the machine to
stop automatically when abnormality
occurs, then investigate the cause.
(Inventor)
Kiichiro Toyoda
(Founder)
‘JUST－IN－TIME’
"What is needed, when
needed, as needed!"
Passenger Type AA (mass-produced
passenger car type A1) production
starts. Year 1936
Taiichi Ohno
(Executive Vice President )
Introduction of ‘Toyota
Production System’
Year 1942
“Elimination of waste”

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• The success of the Toyota Production System is not just because of the tools
of production management such as ‘Kanban’, ‘Kaizen’ etc., it is a culture or a
system that can cultivate ideas and make good products day and night at the
site by the carpenters.
Reference2. The Philosophy of Toyata Production
A culture or a system of cultivating ideas.
• Persist in on-the-spot decision-
making TOP management • The mechanic of lighting up Kaizen
desire.• Process-oriented principles. (The
changing of results depends on the
luck by the time.) • The use of automation.
This steady is the practice of maximum effort and because the results are
influenced by the good or bad luck so do not be glad and sad by turns.
(Process-oriented principles)
The Toyata Production System is a transmission of the good Japanese
traditions nowadays.
“The sincerity and humanity itself is impossible without incident.
However, the lack of them destroys everything.”
Peter Drucker

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Reference 3. The Kanban System
From the beginning until the last process,
take only the required amount of the
required items when required. Then, the
earlier manufacturing process is to supply
only the amount of production which was
taken over. In this way, the Kanban
method prevents over process while being
a tool of putting the overall just-in-time into
practice.
1. The origin of ‘one piece flow’
manufacturing
2. Following with the take-back
process
3. Zero inventory
4. ‘Leveling work’ → Obey the
cycle time
5. Do not make it so fast.

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Reference 4
“Automation with A Human Touch”
1. Immediately stops the line when poor
response occurs.
2. It brings confusions to customers if
a product is produced without handling the real
cause.
3. “Automation with a Human Touch” is not
about "Automation" but to attach humans’
wisdom onto the machine so it will not shut off
automatically.
4. Keep asking the question ‘Why?’ even for 5 or
10 times and is necessary to have a line of does
not want something bad to occur for the second
time.

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Reference 5. Muda (Waste) Elimination
2. Muda of inventory
‘Treasure things’ and ‘the thinking of do not waste’ are the
origin of eliminating muda.
1. Muda of processing 3. Muda of overproduction
4. Muda of waiting 6. Muda of transport5. Muda of repair/rejects

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Reference 6.The Mind of Toyota's manufacturing
"In a company when there is no race to get each
person to add their good ideas to the work they do, I
think this ruins people. Your improvements make the
job easier for you, and give you time to make further
improvements. Unlike in the [Charlie] Chaplin movie
where people are treated as parts of a machine, the
ability to 'add your creative ideas and changes to your
own work' is what makes it possible to do work that is
worthy of humans."
Taiichi Ohno

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3. The Kaizen Philosophy
The world is constantly changing. Therefore, corporations as well as the people are
changing, if countermeasures are not practiced, one cannot survive.
At first, explore the changes that are under the constraints.
There is an infinite ways of changing but in able to survive, change is finite. However, no
one knows what is the BEST changing. Possibility for changes in BEST are hidden
from the changes in non-BEST.
The valuation of whether it is BEST or not is, because the decision is made by the external
world (customers), the decision itself cannot determine and be concluded.
When the evaluation of the outside world is good, then that is the good one.
Therefore, the first thing we need to do is to take action of the changes.
Results will be known if action is taken, the next action can be taken if the results is
analyzed.
Getting cold.
Countermeasure 1: Wear a coat.
Countermeasure 2: Use the heating system.
Countermeasure3: Move to a warmer place.
Select the BEST option
to fit the constraints.

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3. The Kaizen Philosophy
Taking a serious view of the results or the process?
For everything, it is not a big achievement if something successes
according to the plan in our head. Because such a thing has always
already been implemented..
The probability of successful is low, the thing no one wants to do,
no one implements it and therefore, there is a value of trying.
Then try to verify why failures occurred.
Never give up and key to success is in it.
“Our greatest weakness lies in giving up. The most certain
way to succeed is always to try just one more time.”
Thomas Edison

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3. The Kaizen Philosophy
According to the global changes, the method of work has
to correspond in accordance with the corresponding reality.
At first, grope for the correspondence in the constraints.
・New technology
development
・Groundbreaking
material development
・Moves of competitors
・Costumer needs
・Legal regulations
Reality and
constraint
corresponding
Kaizen
A task is defined as a work to achieve a given objective. While Kaizen is
defined as a better way to achieve the business objectives and make
changes to a method.

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4．How to proceed Kaizen?
Organization. Management. Cogitation.
1) Organization: The continuity of developing the entire Kaizen
organization.
・Membership
・Rules and regulations are made.
2) Management: Make an approachment and a mechanism to keep the
management system on track and the activation of Kaizen
activities.
・Select and train a leader.
3) Cogitation：Explain and make the employees consent to the definition of
Kaizen.
・Kaizen education
Organization is set up in order to continue the promotion system at the field level.

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Employees’ opinions, enthusiasm and education are necessary.
4. How to proceed Kaizen?
Promote Kaizen to employees.
1. The way of thinking：
Understand the meaning of Kaizen and urge the participation of Kaizen
activities.
2. Enthusiasm：
Set a notice board and premium for those who are actively involved.
3. Education：
Educate the technology of efficiency improvement and methods.
EnthusiasmEducation
Thinking

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1. Immediate implementation. Immediate action:
If there is any problem, apply Kaizen on the spot.
There are Kaizen chances if problems occurred especially when
the problems only occur occasionally.
Analyze the situation on the spot and investigate the problem.
2. Do not waste time:
Do not conduct special meetings but instead proceed Kaizen.
Seek advice from supervisors and seniors if there is something
to consult and confirm.
3. Do not spend money:
The resolution of trouble cannot be handled by money.
The thinking of whether one can access alternatively cheap and
available for carrying out present item as well as commercial item.
4. Suggestion from others:
Seek suggestions from supervisors, seniors as well as
managers from other departments.
Start at once
Time is Money
Don’t Spend Money
Two heads are better than one
4. How to proceed Kaizen?
Kaizen Implementation

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Invention of CD, personal computer, microwave…
5. Kaizen & Innovation
Innovation
The innovation type of revolution of the world leads to a contribution in
development and spend a lot of time and money on invention. Also again, there
are many developed, invented and copied items, profit as well as the members
who are in charge of it comes to only have a small amount and it often does not
occur.
Characteristics:
1. It needs an enormous cost.
2. A long-term studies is needed.
3. Miscellanies do not occur frequently.
4. Easy to be imitated.
5. Planned implementation. (Analysis of present state, countermeasure,
affirmation, evaluation)
Invention of internet, e-mail, Messenger…
Invention of light bulb, print technology, airplane…

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Productivity can be improved by increasing the productivity which
consumes a lot of time and money and it includes the members and
all the field workers. Also, a good management system that is built is
difficult to be imitated by other companies.
Characteristics:
1. Huge sum of money and does not take time.
2. Possibility of educating the employees.
3. Can respond to daily problems.
4. Difficult to imitate.
5. Take actions immediately.
Kaizen is a system, there is no point in learning techniques
and their own individual cultures.
5. Kaizen & Innovation
Increasing The Productivity

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Kaizen Innovation
Effect Long-term, continuous Short-term, dramatic
Time Fast response Development for a long
time
Change A constant slow Sudden & explosive
Participation All Some elite
Approach Collectivism and systems
approach
Individualism idea
Way Maintenance &
improvement
Scrap & build
Benefit Function in low-growth
economy
Features of high-growth
economy
5. Kaizen & Innovation
Comparisons

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Outbreak of
innovation
Outbreak of
innovation
Ideal innovation pattern
Actual innovation pattern
“The organization or the system is an organization (or a system) that is to
be finished begins to degenerate.” Parkinson’s law
Loss
management
Loss
management
Loss
management
5. Kaizen & Innovation
The Type of Innovation

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Outbreak of
innovation
Outbreak of
innovation
Ideal innovation pattern
Reality innovation pattern
In order to reduce loss management, QC management and
facilities management are implemented to maintain and continue
the status quo.
Loss
management
Loss
management
Loss
management
5．Kaizen & Innovation
QC Management & Facilities Management

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Outbreak of
innovation
Outbreak of
innovation
Ideal innovation pattern
Reality innovation pattern
Kaizen pattern
Kaizen is the better way to explore under restriction limits.
Loss
management
Loss
management
Loss
management
Kaizen
Kaizen
Kaizen
5. Kaizen and Innovation
Kaizen

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6. Practical Kaizen System
What is Kaizen?
Kaizen is about the changing of the method of work without hassles, without
spending money and using the wisdom to make work easy, safe and fast.
Also, write down notes of Kaizen and doing recording is important.
If manifestation is being measured and communized with everyone is possible,
a new Kaizen is born.
• Without hassles
• Without spending money
• Using the wisdom
Kaizen = Reality measures
Enforcement
RecordingCommunization

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6. Practical Kaizen System
Implementation
• In order to promote Kaizen, the important thing is there
must be implementation.
• The traditional proposal system is going to be outdated
in the future. The idea of ‘I am the proposer. You are the
conductor. ’ does not work in the coming years.
• Try to practice it if you have any idea. If the idea is not
good, rethink and try again.

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1. Record the carried out Kaizen activity.
2. Content?
3. Effect?
4. The remaining challenges.
6. Practical Kaizen System
Of Record
Start with the recorded and datalysed work.

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1. Contact the other departments related to the
implementation, discuss and communize the problem.
2. Provide education to the other departments.
3. Pose and review the problems.
Kaizen types Implement
Verification of
effectiveness
Discuss with friends &
superior authorities
Survey about IT &
other departments
Communization
Provides information to other
departments
‘Databaselized’,
education materials
6. Practical Kaizen System
Communization

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