Kaizens

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 IndustryKaizens 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 ie; 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 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 created.
Corrective Action Kaizens - These Kaizens are done 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 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 compilationTo summarise on the qualification method of wheather a kaizen is fit for compilation, would require the same to go through the following pre-requisites:-
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 head”
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.