Kaizen is small improvements and a change for better.It must be accompanied by change of method. The Kaizen concept stimulates productivity improvement as an ongoing process in any company.It is a practice oriented strategy which leads to creation of culture of improvement It is more a way of life or at least a cultural approach to quality improvement. The implementation of philosophy of Kaizen can be achieved through involvement of employees to effect improvements.
Kaizen –A Necessity for the Industry
Kaizens can be implemented in the industry by improving every aspect of business process in a step by step approach, while gradually developing employee skills through training and increased involvement. The principle are:
- human resources are the most important company asset
- process must evolve by gradual improvement rather than radical changes
- improvement must be based on evaluation of process performance
By practicing Kaizen culture, managers demonstrate commitment to quality. Also, the workers with adequate support from managers become a major source of improvement
Kaizen system is simple,but its implication are far reaching. These can be in the area of Productivity, Quality, Cost, Delivery, Safety & Morale of Employees
- Q would mean more accurate
- C would mean cheaper, lesser value
- D would mean lesser cycle time or lead time, faster and more quantity.
- S would mean safer,easier & comfortable working.
- P is a derivative or a combination of any of the above QCDSM. However,there could be Kaizen, which is implemented primarily to improve productivity. Such a productivity improvement kaizen may also indirectly effect cost and/or quality and/or safety etc.. Hence, the categorisation of a kaizen should be done based on what it was originally intended for and not based on what all could be the eventual spin-off or side benefits
Kaizen would always involve a change in the method of doing. It could be esign change, procedure change etc
Kaizen vs Large Improvements
A kaizen is a small improvement
without much data analysis.A problem solved through the method of using six sigma techniques would not qualify as a kaizen for the purpose of compilation .Hence a kaizen done through “dataless”improvements would qualify as a kaizen.
Types of Kaizens :
Primarily two types of kaizens
- Idea Kaizens - These Kaizens have no why-why analysis.
If any why-why analysis is done normally it would always
reach the same conclusion that “no one thought of it
before”. These Kaizens have been done due to an idea
- Corrective Action Kaizens - These Kaizens are done to correct a
problem and would have a proper why-why analysis.
Originality, impact of kaizen & quality of analysis varies in both case as under :-
Heads and Hands
||Corrective Action Kaizen
||High & Must
Any kaizen involving usages of different technologies would not qualify because the person has not used his/her innovativeness/creativity in doing this kaizen but used an already existing technology to replace the “doing” method. This may have resulted in benefits but does not qualify for this compilation, as the doer has not used his” hands and head”.
Pre-requisites of a Kaizen for compilation
To summarise on the qualification method of wheather a kaizen is fit for compilation, would require the same to go through the following pre-requisites:-
Why this site?
- Kaizens should be a change for the better with a change in method.
- The Kaizens should be a data-less improvement.
- The Kaizen must be done by persons at the operator/supervisor level.
Could be proposed by seniors also.
- The Kaizen must follow the “head and Hands” principle.” Hands and/or
- The Kaizens must be classified as an “Idea” or “Corrective” Kaizen.
- Kaizens must not only be from the shopfloor but also from the office area,
- Scrapyard, stores, etc.
- Indian manufacturing industries in their own way have been regularly and constantly striving towards improvement (kaizens) whether it is in the process or product in the machine or design in saving time or cost, in reducing inventory or wastage.
- In the area of manufacturing there has been a tremendous contribution from the Indian industry thus generating plethora of Kaizens over the period of time.
- In the spirit of sharing & learning, CII proposes to collects and compile one lakh kaizens with a view to make this learning available to the rest of the Industry. CII aims to create a website on these kaizens as a service to the Industry at large.
- Through these kaizens are primarily from this manufacturing industry it is also purposed to extend the same to various other sectors like education, government service and so on.
To know more about KAIZEN please click here to download the presentation PDF
Compiled by:- Mr. C Narasimhan, Chief mentor - ACMA Center of Technology, & President - Sundran - Clayton Ltd