1. KM 1
KA IZ E N
Management
Characteristics of
Japanese Production Systems

2. KM 2
KAI-ZEN
Continuous improvement V: Green walking

3. KM 3
What is Industry ?
Input Output
Industry
Man-power Products
Machines Services
Materials
Methods Technology
Skill
(4M’s)

4. KM 4
Evaluation of the output ?
Q, C, D
Input Output
Industry
Q: Quality
C: Cost KAIZEN
D: Delivery action

5. KM 5
KAIZEN is a feedback
Input Output
Industry
KAIZEN
action
KAIZEN is a corrective action

6. KM 6
KA IZ E N is a Japanese word
改 : change
善 : better

7. KM 7
Definition of KAIZEN

8. KM 8
Definitions of KAIZEN
1. A selection of better means or
a change of current method
for achieving an objective.
1. An accumulation of small changes
The Japan HR Association

9. KM 9
How do farmers pack
oranges?

10. KM 10
I need
help.

11. KM 11
Productivity: 1 net per min.

12. KM 12

13. KM 13
Productivity: 5 nets per min. with 2 workers

14. KM 14
A selection of better means or
a change of current method
for achieving an objective.
Can you think of a better
method to pack oranges?

15. KM 15
Productivity: 5 nets per min. with 1 worker

16. KM 16
Definitions of KAIZEN
1. A selection of better means or
a change of current method
for achieving an objective.
1. An accumulation of small changes
The Japan HR Association

17. KM 17
Chopsticks

18. KM 18
Children hold their chopsticks improperly

19. KM 19

20. KM 20
Training
… but still difficult to use

21. KM 21
Soft paddings (Japanese fish paste)
… for some children, balancing the chopsticks is difficult

22. KM 22

23. KM 23
Training chopsticks

24. KM 24

25. KM 25
KAIZEN is
a continuous improvement
Continuous = again and again

26. KM 26
Question

27. KM 27
Where is a division between our
KAIZEN is a small change to
jobs and KAIZEN?
make something better.
- I picked up a garbage and
put it in a trashcan.
- I wiped the windows and
made them clean.
- I used a mop to clean the gasoline
left on the floor.

28. KM 28
A waitress was working
at a restaurant in Tokyo

29. KM 29
KAIZEN is a small change
A small change of a method (approach)
Any way to pick up the mop?
Any way to store the mop?
Any way to carry the mop?

30. KM 30

31. KM 31

32. KM 32

33. KM 33
toothbrush

34. KM 34
Swatter

35. KM 35
tweezers

36. KM 36

37. KM 37
Improvement by
changing methods
How do we change methods?

38. KM 38
KAIZEN Steps

39. KAIZEN Steps KM 39

40. KM 40
KAIZEN Steps Review

41. Remove thisKM 41
Elimination sliding door
What is the use of the sliding doors?

42. KM 42
Why are shoe box doors needed?
Before After
1

43. KM 43
Why is the toilet cover needed?
Before After

44. CDG(Paris) Toilets KM 44
Frankfurt
Hong Kong Tokyo

45. KM 45
No sleeves down-jacket is easy to work
Before
After

46. KM 46
Reduce
A fluorescent light
bulb was removed.
Reduce the number of lights

47. KM 47
Before
Why two bricks?

48. KM 48
Parking Lot

49. KM 49
One brick is enough to stop a car
Before
After 1

50. KM 50
Zebra Zone
1

51. KM 51
Side lines of
the zebra zone
are removed.
Before
After
1

52. KM 52
Long or short brush part?
Before After

53. KM 53
toothbrushes

54. KM 54
Change
Ribbon waving? Visual Management

55. KM 55

56. KM 56
Pinwheel
turns around
Visual Management

57. KM 57
The hollow about the key hole
smoothes the key movement.
Before
After 1

58. KM 58
To oil the pan, a small teapot is
more convenient than a ladle.
Before
After

59. KM 59

60. Stairways at the railway station KM 60
should have signs of up and
down.
Before
After

61. KM 61
At JR Kurume Station

62. KM 62

63. KM 63
Rush Hour

64. KM 64
Before
After

65. KM 65
Hanging Straps in JR trains

66. KM 66
Hanging strap in
Hong Kong subways
The Japan HR Association

67. KM 67
Suggestion System
vs.
KAIZEN Suggestion System

68. KM 68
Suggestion System
You suggest your ideas, and I will
examine them and implement some
of your ideas later.

69. KM 69
Suggestion System Concept
Reward
Idea
Idea

70. KM 70
KAIZEN Suggestion System
Implemented KAIZEN ideas must be
submitted
EN
KAI Z t
e
s he

71. KM 71
Suggestion System
Workers’
responsibility Management responsibility
Idea
generation
Workers’ responsibility Management
responsibility
KAIZEN Suggestion System

72. KM 72
Suggestion System
Propose improvement ideas for any
activity in the company.
KAIZEN Suggestion System
Propose only improvement ideas which
will improve your own work.

73. KM 73
KAIZEN
1
Memo

74. KM 74
AOTS KAIZEN

75. KM 75
AOTS KAIZEN

76. Reward KM 76
For an excellent KAIZEN, a large amount of reward
is given (5000 yen, 10000 yen, 50000 yen)

77. KM 77
Award Payment for Each
KAIZEN Suggestion (2008)
0 50 100 150 200
0 18
1-99 24
100-299 110
Jpn Yen
300-499 109
500-999 163
1000-2999 83
3000-4999 11
5000+ 10 Average 385 yen
Surveyed 528 companies

78. KM 78
2008
Among (527) companies,
Employees who suggested at lease one idea
Total number of employees
74.4%
Implemented suggestions
All suggestions
88.7% 1

79. KM 79
Different styles of change
1. Small change --- By individual effort, a better way
of proceeding a job is
(KAIZEN) considered. (Idea creation)
2. Medium change --- By group effort, a better way is
proposed by following
(Small group predetermined steps (or rule).
activities)
3. Big change --- By investments in new technology or
equipment, dramatic alterations are
(Innovation) achieved.
2

80. KM 80
Process
Tool Change Change
Tomato Juice

81. KM 81
Newspaper
Article
Nikkei News,
Nov. 22,1997

82. KM 82
Hydroponics Cultivation
6000 tomatoes
http://www.arigat.net/kandoh.html 1

83. Tomato Juice
KM 83
Process Material
Tool Change Change Change
Input Output
Industry
Man-power
Machines
Materials
Methods KAIZEN
(4M’s) action
2

84. Two Attitudes KM 84
Management Breakthrough
Staff
Floor people Status quo

85. KM 85
Japanese firms
n
io
Management
v at
no
In
Z EN
Staff AI
K
q uo
s
Floor people tu
S ta
Non-Japanese firms
n
Management a tio
ov EN
Inn Z
KAI
Staff quo
s
tu
Sta
Floor people

86. KM 86
Fin