Kaizen

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 Industry

Kaizens 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 principles 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
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 affect 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 Kaizens:

Primarily two types of Kaizens

• Idea Kaizens - These Kaizens have no why-why analysis. If any why-why analysis were 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.

Originality, impact of kaizen & quality of analysis varies in both cases as under: -

	Corrective Action Kaizen	Idea Kaizen
Originality	Not Necessary	High & Must
Impact	High &Must	-Do-
Quality Analysis	-Do-	Not Required

Heads and Hands

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 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: -

• Kaizens should be a change for the better with a change in method.
• The Kaizens should be a data-less improvement.
• Persons at the operator/supervisor level must do the Kaizen. 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 shop floor but also from the office area,
• Scrap yard, stores, etc.