KKAIZEN AIZEN MMANAGEMENT ANAGEMENT SSISTEMISTEM

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What is What is Kaizen Management SyistemKaizen Management Syistem ? ?

KMS KMS is...is...

... a system of continuous improvement ... a system of continuous improvement in quality, technology, processes, in quality, technology, processes, company culture, productivity, safety company culture, productivity, safety and leadership. and leadership.

Toyota companyToyota company

What is What is Kaizen Management SystemKaizen Management System ? ?

Kaizen is a Japanese philosophy that focuses on Kaizen is a Japanese philosophy that focuses on continuous improvement throughout all aspects of life.continuous improvement throughout all aspects of life.

When applied to the workplace,as a Kaizen When applied to the workplace,as a Kaizen

Management System Kaizen activities continually Management System Kaizen activities continually improve all functions of a business, from manufacturing improve all functions of a business, from manufacturing to management.to management.

By improving standardized activities and processes, By improving standardized activities and processes, Kaizen aims to eliminate waste.Kaizen aims to eliminate waste.

TranslationTranslation

In Japanese this is pronounced In Japanese this is pronounced "kaizen"."kaizen".

改 改 "kai""kai" means means "change""change" or or "the action to correct". "the action to correct".

善 "zen""zen" means means "good"."good".

The word Kaizen means The word Kaizen means "continuous improvement". "continuous improvement".

HistoryHistory

Kaizen was first implemented in several Kaizen was first implemented in several Japanese businesses during the country's Japanese businesses during the country's recovery after World War II, including Toyota, recovery after World War II, including Toyota, and has since spread out to businesses and has since spread out to businesses throughout the world.throughout the world.

This method became famous by the book of This method became famous by the book of Masaaki Imai “Kaizen: The Key to Japan's Masaaki Imai “Kaizen: The Key to Japan's Competitive Success.” Competitive Success.”

Kaizen as a reason of Japanese Kaizen as a reason of Japanese businesses successbusinesses success

In business Kaizen encompasses many of the In business Kaizen encompasses many of the components of Japanese businesses that have components of Japanese businesses that have been seen as a part of their success. been seen as a part of their success.

Quality circles, automation, waste categories, Quality circles, automation, waste categories, suggestion systems, just-in-time delivery, suggestion systems, just-in-time delivery, Kanban and 5S are all included within the Kanban and 5S are all included within the Kaizen system of running a business.Kaizen system of running a business.

The ProcessThe Process

The quick and easy kaizen process works as follows:The quick and easy kaizen process works as follows: 1. The employee identifies a problem, waste, or an opportunity for 1. The employee identifies a problem, waste, or an opportunity for

improvement and writes it down. improvement and writes it down. 2. The employee develops an improvement idea and discusses it 2. The employee develops an improvement idea and discusses it

with his or her supervisor. with his or her supervisor. 3. The supervisor reviews the idea within 24 hours and encourages 3. The supervisor reviews the idea within 24 hours and encourages

immediate action. immediate action. 4. The employee implements the idea. If a larger improvement idea is 4. The employee implements the idea. If a larger improvement idea is

approved, the employee should take leadership to implement the approved, the employee should take leadership to implement the idea. idea.

5. 5. The idea is written up on a simple form in less than three minutes. The idea is written up on a simple form in less than three minutes. 6. Supervisor posts the form to share with and stimulate others and 6. Supervisor posts the form to share with and stimulate others and

recognizes the accomplishment. recognizes the accomplishment.

5S5S

1.Standardize1.Standardize

2.Sort2.Sort

3.Straighten3.Straighten

4.Sweep4.Sweep

5.Self-discipline5.Self-discipline

Waste Categories and Waste Categories and 9 9 Wastes To Be EliminatedWastes To Be Eliminated

1. 1. Work-in-process.Work-in-process. Stocking items not immediately needed Stocking items not immediately needed 2. 2. Quality.Quality. Producing defective products. Producing defective products. 3. 3. Facilities.Facilities. Having idle machinery and breakdowns, taking too long Having idle machinery and breakdowns, taking too long

for setup. for setup. 4. 4. Expenses.Expenses. Overinvesting for required output. Overinvesting for required output. 5. 5. Indirect laborIndirect labor. . Excess personnel due to bad indirect labor system. Excess personnel due to bad indirect labor system. 6. 6. Talent.Talent. Employing people for jobs that can be mechanized or Employing people for jobs that can be mechanized or

assigned to less skilled people.assigned to less skilled people.7. 7. Motion.Motion. Not working according to the best work standards.Not working according to the best work standards.8. 8. Product Design.Product Design. Producing products with more functions than Producing products with more functions than

necessary.necessary.9. 9. New-product run-up.New-product run-up. Making a slow start in stabilizing the Making a slow start in stabilizing the

production of a new product. production of a new product.

Three Key CharacteristicsThree Key Characteristics

1.Permanent method changes.1.Permanent method changes. Change the Change the method. Once the change is made, you can’t method. Once the change is made, you can’t go back to the old way of doing things. go back to the old way of doing things.

2.Continuous flow of small ideas.2.Continuous flow of small ideas. The smaller The smaller ideas, the better. Kaizen is small ideas.ideas, the better. Kaizen is small ideas.

3.Immediate local implementation.3.Immediate local implementation. Be realistic. Be realistic. Kaizen is done within realist or practical Kaizen is done within realist or practical constraints. constraints.

Kaizen TimeKaizen Time

In some In some Canon plantsCanon plants, the foremen are told to , the foremen are told to set aside the half-hour as set aside the half-hour as Kaizen TimeKaizen Time – time – time to do nothing but thinking improvement in the to do nothing but thinking improvement in the workshop. The foremen use this period to workshop. The foremen use this period to identify problems and work on Kaizen identify problems and work on Kaizen programs. Factories are advised not to hold programs. Factories are advised not to hold meetings during this 30-minute period, and meetings during this 30-minute period, and foremen should not even answer the telephone foremen should not even answer the telephone then. then.

The 3 Evils of MeetingsThe 3 Evils of Meetings

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Benefits Benefits

Kaizen Management Sistem empowers Kaizen Management Sistem empowers employees, enriches the work experience and employees, enriches the work experience and brings out the best in every person.brings out the best in every person.

Serves as a barometer of leadershipServes as a barometer of leadership. . Kaizen helps eliminate or reduce wastes and Kaizen helps eliminate or reduce wastes and

improves quality, safety, cost structures, improves quality, safety, cost structures, delivery, environments, product and customer delivery, environments, product and customer service.service.