Kaizen

Kaizen is a Japanese philosophy which means continuous improvement where the words ‘Kai’, means continuous and ‘zen’ means improvement. Kaizen also translates to ‘Kai’ to mean change and ‘zen’ to mean good, or for the better. Kaizen process when performed correctly, humanizes the workplace, and eliminates overly hard work i.e., the process suggests a humanized approach to workers and to increase productivity. The main motive is to nurture the company’s people as much as it is to praise and encourage participation in kaizen activities.

Kaizen is a system which encourages every employee of the organization whether from senior management or the lowest rank employee to come up with small improvement suggestions on a regular basis. The ideas here is are not to go for major changes as, Kaizen focuses on making little changes of improving productivity, safety and effectiveness while reducing waste on a continuous basis. The suggestion taken from the employees are not limited to a specific area like production or marketing but changes that can be in any are requiring improvements. The philosophy of Kaizen is based on the fact is to do it better, make it better, and improve it even if it isn’t broken, because if we don’t, we can’t compete with those who do.

Kaizen is all about continuous improvement that encompasses components like Quality circles, automation, suggestion systems, just-in-time delivery, Kanban and 5S. Kaizen involves setting standards and then continually improving those standards with providing needed training to achieve the standards and maintain them on an on-going basis.

1. Gemba – Gemba is a Japanese word for ‘real place,’ where the value-adding activities to satisfy the customer are carried out. The Gemba place can be where the product is developed or produced or sold or made. In the service sectors, Gemba is where the customers come into contact with the services offered. Gemba is important to Kaizen as most managers prefer their desk thus, come in contact with reality only through reports or other meetings.
2. Gembutsu¸ is a Japanese word meaning some unconformable physical or tangible things like out of order equipment or scrap which can be felt. If a machine is down or a complaining client, the machine itself is gembutsu then, go to Gemba and have a good look at the machine. By looking at the machine, and asking the question “why” several times, to probably find out the reason for the breakdown on the spot.

Kaizen Steps

Kaizen process follows the below listed steps

1. Defining the problem – Defining the problem is a first activity to undertake for initiating the Kaizen process.
2. Gemba walk and Document the current situation – It involves making observation and conducting meetings so as to gather information and identify inefficiencies in the present processes especially where the Gemba is or the places where value process are taking place.
3. Visualizing the ideal situation – Developing an ideal blueprint for the future situation which is achievable by implementing Kaizen
4. Defining the measurement targets – After finalization of the blueprint for the ideal solution to the present inefficiencies, make measurable targets so as to quantify the gains due to Kaizen implementation
5. Brainstorming solutions to the problem – Brainstorming helps in listing possible the solutions whose implementation will develop Kaizen plan, implement plan, measure, record and compare results to targets, prepare summary documents and create short term action plan, on-going standards and sustaining plan.

Since Kaizen aims for improvements in productivity, effectiveness, safety, and waste reduction, some of the features of Kaizen are,

1. Less waste – The inventory is used more efficiently as are employee skills.
2. Higher level of satisfaction – Increases a satisfaction as it has a direct impact on the way things are done.
3. Improved commitment – Team members have more of a stake in their job and are more inclined to commit to doing a good job.
4. Improved retention – Satisfied and engaged people are more likely to stay.
5. Improved competitiveness – Increases in efficiency tend to contribute to lower costs and higher quality products.
6. Improved consumer satisfaction – Coming from higher quality products with fewer faults.
7. Improved problem solving – Looking at processes from a solutions perspective allows employees to solve problems continuously.
8. Improved teams – Working together to solve problems helps build and strengthen existing teams.