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What is Kaizen?
There are 2 approaches to problem solving: The 1st involves innovation - applying high cost solutions such as state of the art technology
The 2nd uses common sense tools, checklists & techniques that do not cost money.
Kaizen = Kai [to take apart and make new] Zen [ to think about so as to help others]
Definition :
DEFINITION
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The Kaizen philosophy is drawn from the Japanese word Kai which means continuous and Zen meaning improvement or wisdom. The Kaizen management philosophy, therefore, is defined as making continuous improvementslow, incremental but constant.
The Japanese word "KAIZEN" means improvement, improvements without spending much money, involving everyone from managers to workers, and using much common sense. The Japanese way encourages small improvements day after day, continuously. The key aspect of KAIZEN is that it is an on-going, never-ending improvement process. The Kaizen way encourages small day-to-day yet continuous and never-ending improvement process involving everyone from managers to workers using the most basic tenet of survival: Common sense. In business applications, Kaizen covers most of the modules of successful Japanese concepts. Kanban, 5S, quality circles (QCs), just-in-time (JIT) delivery, automation, suggestions systems, etc., are all embedded into the Kaizen system of modern business management.
HISTORY
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The story of the Kaizen miracle started in the 1930s. Sakichi Toyoda, founder of Toyota,
In 1950 Toyota implemented quality circles leading to the development of Toyotas unique Toyota Production System. Toyota System is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. These continual small improvements (Kaizen) add up to major benefits.
In 1986 Masaaki Imai introduced to the Western world the Japanese term Kaizen and made it famous through his book, Kaizen: The Key to Japan's Competitive Success.
In 1997 Imai introduced an evolved form of Kaizen in his book Gemba Kaizen:
Kaizen
Customer Supplier
Why Kaizen?
bridge the gap between where we are now and where we need to be.
Top management commitment Middle management commitment Work force commitment Setting up an organization dedicated to promote Kaizen Appointing the best available personnel to manage the Kaizen process Conducting training and education Establishing a step-by-step process for Kaizen introduction.
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Every time a new measure is implemented, it must be seen how it goes, check the results, search out, admit mistakes, and try to do better in the next attempt. - By TAICHI OHNO
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v Develop need and understanding of kaizen v Create a vision on kaizen v Create a structure for kaizen implementation v Provide kaizen training v Design promotional activities v Develop recognition systems v Design review and monitoring systems The efficiency, growth and development of an organization, what ever may be type of organization depend on the capability of the personnel and the technology. The capability if the person depends on the type of training and the motivation
Team based & cross functional Team members can be from various functions of the business. Top management participation is encouraged.
Planned & tied to business goals Events are planned in advance and tied to business goals and or value streams. Planning is critical to the success of the event. Focused in scope Events are very focused, Dont take too much on at one time!
Short term, fast & iterative Events last approximately 2 to 5
quick results. Measurable results. Establish the baseline, and measure the change! Use many of the tools found in the House of No Waste Events may use a variety of the Lean Tools (5s, Cellular, Pull..)
A Learning Experience Every member of a Kaizen Team will walk away from the event learning something new!
5s
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Seiton
The next step of kaizen is Seiton. This concept is dealing with how we arrange things so that it make us easy to get those things right away once we need them. It is clear that it involves at least two actions; how we keep those things and standard of how urgent we need them. It
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Well, Japanese people have a good tool in order to get rid of this problem. They call it red tag movement. Below are steps to guide us to implement red tag movement. Provide come pieces of tags, (of course, they must not in red, we can use any color, as long the same color for
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Seiso
Seiso, the third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up the workplace and giving it a 'shine'. Cleaning must be done by everyone in the organization, from operators to managers. It would be a good idea to have every area of the workplace assigned to a person or group of persons for cleaning. No area should be left uncleaned. Everyone should see the 'workplace' through the eyes of a visitor - always thinking if it is clean enough to make a good impression.
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Seiketsu
The fourth step of "5S", or seiketsu, more or less translates to 'standardized clean-up'. It consists of defining the standards by which personnel must measure and maintain 'cleanliness'. Seiketsu encompasses both personal and environmental cleanliness. Personnel must therefore practice 'seiketsu' starting with their personal tidiness. Visual management is an important ingredient of seiketsu. Color-coding and standardized coloration of surroundings are used
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Shitsuke
The last step of "5S", Shitsuke, means 'Discipline.' It denotes commitment to maintain orderliness and to practice the first 4 S as a way of life. The emphasis of shitsuke is elimination of bad habits and constant practice of good ones. Once true shitsuke is achieved, personnel voluntarily observe cleanliness and orderliness at all times, without having to be reminded by management.
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