KAIZEN is based on making little changes on a regular basis which involves improving quality, productivity, safety and effectiveness while reducing waste.
KAIZEN principles are:
> Elimination of all kinds of waste
> Shortening lead time
> Providing the best quality at a lower cost
> Developing the best work standards
Examples of KAIZEN methods are:
> Promotion of 5S
> Layout optimization/improvement
> Process improvement/time reduction
> Quality improvement/quality assurance
> Cost reduction
> Accounting/Management improvement
> Elimination of waste in conveyance and motion
> Elimination of waste in accumulation
> Visual control
> Multi-skill development/standardization of work
> Inventory control
Plan-Do-Check-Act (PDCA): It is important to implement KAIZEN activities on a regular basis on the strategy of PDCA (Plan-Do-Check-Act) with focus on eliminating waste, visually displaying the production plan, progress status and guiding the workers towards continuous improvement by repeating the PDCA cycle.
5S: 5S is the name of a workplace improvement method that uses a list of five Japanese words which all start with S:
1. Sorting (Seiri)
2. Setting-in-Order (Seiton)
3. Shining and Sweeping (Seiso)
4. Standardizing (Seiketsu)
5. Sustaining the Practice (Shitsuke)
The benefits of 5S includes:
1. Reduction of lost time
2. Reduction of machine failure
3. Reduction of time for material delivery
4. Reduction of searching time for tools
7 Wastes (Muda):One popular method of KAIZEN is the elimination of 7 types of waste (muda) to achieve efficient and rational production. It ensures that an enterprise simply produces only what is necessary at the right time and helps to visualize the production to enable an enterprise plan and monitor its operations effectively.
The 7 wastes KAIZEN aims to eliminate are:
1. Overproduction
2. Waste of waiting
3. Waste in transportation
4. Waste in processing
5. Waste of inventory
6. Waste of motion
7. Defects