Monday 10 December 2018

Lean Kaizen: Kaizen principles | Types & Examples

Lean is a methodology that eliminates waste and boosts efficiency. Kaizen means continuous improvement. This course merges both philosophies. Lean Kaizen helps you get rid of waste and continuously implement best practices.

Lean 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 orient 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 achieve through involvement of employees to effect improvements.

A Necessity for the Industry Kaizen 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.

Kaizen Principles - Lean Thinking

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 i.e.; PQCDSM.

  • 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 categorization 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 design 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 “dateless” improvements would qualify as a kaizen.

Types of Kaizen:

Idea Kaizen

These Kaizen have no why-why analysis. If any why-why analysis process is complete normally. It would always reach the same conclusion that “no one thought of it before”. These Kaizen have been complete due to an idea creates.

Corrective Action Kaizen

These Kaizen can complete to correct a problem and would have a proper why-why analysis. Any kaizen involving usages of different technologies would not qualify because the person has not used his/her innovativeness/creativity in doing this Lean 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 summarize on the qualification method of whether a kaizen is fit for compilation, would require the same to go through the following pre-requisites:-

  • Kaizen should be a change for the better with a change in method.

  • The Kaizen should be a data-less improvement.

  • The Kaizen must be complete by persons at the operator/supervisor level. Could be propose by seniors also.

  • A Kaizen must follow the “head and Hands” principle.” Hands and/or head”

  • The Kaizen must be classified as an “Idea” or “Corrective” Kaizen.

  • Kaizen must not only be from the shop floor but also from the office area,
    Scrapyard, stores, etc.

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