Monday 17 December 2018

The Concept of Kaizen

The concept of Kaizen encompasses a wide range of ideas. The term Kaizen is often use as one of the strategies the improvement in management in industry, banking, services etc., both in the private sector or the Government, which has proven to be a lot of delivering success company corporate Japan in winning a tight competition in the business.

Even during this management in improving productivity, quality and management alternatives originally born and initiated by management experts from Western countries.

But the presence of the repair management system kaizen, the concept has gotten attention special management analysts after seeing rapid economic developments in Japan are often troublesome American hegemony in the global economic scene.

Concept of Kaizen

History of Kaizen – concept

The phenomenon of economic growth Japan's post WORLD WAR II rebuilding of motivating the ruins of war and the sent an expert survey of the U.S. named Dr. w. Edward Deming who try to help Japan to rebuilding Japan's economy so that the concepts of Deming starting in 1970-80s have been applied by the company in Japan which is famous for "14 key Dr. Deming" and surprisingly successful application of the concepts of deeming in the U.S. Government's new Japanese industry was interested in the concept.

But the concept of deeming who was later better known as kaizen concept extensively recently introduced by Masaaki Imai, in his book "Kaizen: the key to Japan's competitive success" (1986).

Try conclusions Europe Japan Centre about Kaizen Japan which reveals that:

"Kaizen tells us that only by continuously remain aware and make hundred thousand small increase, it is possible for the goods and services produce quality authentic so that satisfy customers.

The easiest way of achieving it is by participation, motivation and continuous improvement of each and all of the employees in the organization. Staff participation is dependent on the in committer senior management, a clear strategy and fortitude because of kaizen is not shortcut but a process that runs continuously to create a desired result. " (Cane, 1998:265)

The Meaning of Kaizen

A Kaizen is derived from the word KAI means repairs and ZEN means better. The Kaizen means improvements could be interpreted. Kaizen means continual improvement (continuous improvement). A key feature of the kaizen management, among others, pay more attention to the process and not a result, cross-functional management and use the circle of quality and other equipment to support continuous improvement.

Kaizen or continuous improvement always hand in hand with Total Quality Management (TQM). Even before the philosophy of TQM is completed or before the quality system can be implemented in a company then this philosophy will not be implement.

TQM philosophy

So that continuous improvements this is inherent in the TQM philosophy itself. So the Kaizen can also constitute a unity of a comprehensive and integrated view which has a characteristic:

  • Customer-oriented.

  • Quality control thoroughly (Total Quality Management)

  • Robotics

  • Quality control Cluster

  • System suggestions

  • Automation

  • Disciplined work place

  • Keeping productions

  • Kanban

  • The refinement and improvement of quality

  • Timely

  • Flawless

  • Small group activities

  • Partnerships between managers and employees

  • New product development

The Key To Implementation Of Kaizen

Broadly speaking there are eight major key or just in time implementation of kaizen in industry events, namely:

Produce products according to the schedule that is based on customer demand.

Kaizen system usually produces the production in accordance with customer orders with pull production systems (pull system). Who is assist by the use of Kanban card.

Produced in small numbers (small lot size)

Another characteristic is produce in small amounts.  In accordance with the request of the customers will save costs and resources.  In addition to eliminating the preparation of goods in the process of which is a type of waste that can be avoid by using scheduling production processes. It also use the pattern production mix evenly (Heijunka) which mean heijunka is producing an assortment in a single production line.

Eliminate waste

To avoid wastage in the inventory, purchasing and scheduling by using the Kanban card system. That supports a pull production systems, in addition to generating a production. Well since its inception i.e. abstinence receive, process and abstinence submit product defects by collaborating.

With suppliers with inventory that is reducing the amount of stuff.  That is dating, eliminating buffer inventory, reduce purchase costs, improve the handling of raw materials, catch up in inventory a small amount and get a reliable supplier.

Fix the flow of production

The production is done by Setup based on five disciplines at work i.e. 5-S, among others

    • Seiri or sorting that is a work place discipline by the separation of many tools or components with respect.  To each so as to look it up later when need would be easier.

    • Seiton or Setup that is a work place discipline by performing functional storage and waste time to find stuff. Seiso or cleanup i.e. discipline tempt work by doing cleanup as an examination and the level of cleanliness.

    • Seiketsu or establishment/maintenance i.e. visual management and government officer 5-S such as marking, announcements, labels, cable settings, code, etc.

    • Shitsuke or conditioning, namely the formation of habits and work that were discipline.

Refining product quality

One of them is to improve the quality of the product depends on your view of the principle of management i.e. maintain control of the process and make it responsible for achievement of quality, improve management quality, against quality control of the product depends on your firm, authorized the work to enable controlling quality products, requires correction of defective products by employees, to achieve 100% against that product quality and commitment to get a long-term quality educator.

People who responds

The application of the Kaizen System, which uses the pillar of finance, marketing, HR, but uses cross-disciplinary or cross-functional so that all employees have to master the entire hierarchy and the position and errors in the process have always been marked with the fact that all the products responsible for achieving a good product and preventing the occurrence of errors.

Remove the uncertainty

To remove uncertainty with the supplier in a relationship lasting manner and have one supplier that its location adjacent to a company who still relatives with the owner of the company, is in the process of production by means of applying pull production system with the help of Kanban card and production mix evenly (Heijunka)

The emphasis on long-term maintenance.

Characteristics of maintenance by holding on a long-term contract, improving quality, flexibility in organizing goods, ordering in small amounts many times, improving continuous and sustainability.

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