What is Kaizen ?

 Kaizen

There are many tools that help you to increase the productivity. Right? But there is nothing like 'Kaizen'.

Let's get a dive into this to understand it's alpha and omega.

What is Kaizen?

Kaizen is a combination of two words 'Kai' meaning change and 'Zen' meaning Good or Better so its complete meaning becomes 'change for better'. It is a sino-japanese word for 'improvement' . A strategical process control that is used to improve the quality in  each aspect of business.It is a continuous improvement process where we can improve our product continuously. Previously it could be used in business only but now because of its popularity,it is implemented in many fields like our personal life,work life,social life etc. Implementing Kaizen is not only responsibility of an individual but involves each member who is directly associated with organisation.

Each and every individual irrespective of his designation post or level in the hierarchy contributes by small improvements and changes for the entire system. It aims to bring organisational success as it not only concentrates on manufacturing process but also involves other departments as well. 

Historical links

After World War II the economy of Japan was completely collapsed General Macarthur(American) wanted to help Japanese to give a boost to manufacturing companies to give its benefits to the American troops living in Japan. This was the seed for Kaizen. It was first seen in Japanese car manufacturing company Toyota. Masaaki imai made this term popular in his book 'Kaizen:The key to Japan's competitive success'

Features of Kaizen

1.Takes ideas from workers.

2.Improves workers' motivation by increasing them to take ownership for their work.

3.Improves the processes which gives better results for the organisation. 

4.Because of being continuous important tool it removes or issues from the base.

5.From top level to the bottom level all employees are responsible for the continuous improvement in their organisation.

6.Enables employees to come up with ideas and encourages managers to implement them to improve processes.

Principles of Kaizen

1. Improve everything continously- Remember,Don't run too fast for major changes,make changes on minor points on regular basis to get major improvements. 

2. Abolish old and traditional concepts-In the modern world don't use obsolete methods or tools for your organisation.

3.Waste and problems are opportunity- Try to extract more good things and positivities from Waste and problems respectively. 

4. If anything is wrong make it correct- Obviously you require to check again and again for you faults if any exists correct it. 

5. Empower everyone to participate in a problem solving- One person cannot give the exact solution of your problem so it's better to add more professionals to the discussion. You will get a variety of views.

6. Be Transparent-Let everyone knows your metrices 

7. Receive opinions and information as gifts from Multiple people.

8. Know Your Customer-Knowing about whom you are selling your product or service is very compulsory.Identify their interest to enhance their experience. 

9. Improvements has no limits-Never stop improving.

10. Be economical-Don't use very much to implement all changes at once put them aside for future as well.

The 7 Wastes (Muda)

Developed by Taiichi ohno,Chief engineer at Toyota.

Kaizen gives the perfection by removing wastes (called Muda in Japanese) in the workplace (called Gemba in Japanese). 

The main objective of Kaizen is to produce without wastes by improving processes.

These 7 mudas are discussed below.

1.Delay-Time spent in a queue means no value being added. This is a waste producing when you spend time to wait for or next step occur.

2.Transport-It includes unnecessary movement of products,materials, equipment etc. as it can lead to more wear and Tear, unnecessary time, work and exhaustion etc. 

3.Inventory-Excess inventory is also waste.  It is very clear that having more inventory than required can lead to problems like product defects or damage material, maintenance etc. Excess inventory is caused by overpurchasing,producing more than a customer needs etc. Suppose that the raw material required for production is 1 tonne and you ordered for 2 tonne.This 1 tonne of extra raw material would be kept in your inventory obviously this would be a kind of waste until it is used.

4.Motion-It includes unnecessary movement of machinery,tool,people of the organisation. In very simple words an employee (for ex.)moving unnecessarily in the organisation gossiping,doing nothing is a kind of waste. 

5.Overproduction-It usually occurs when manufacturing something before it is required.In some proportion this waste has a little relation with inventory also(what you gonna do with this unsold product.

6.Overprocessing- It includes Doing more work or applying more steps in production or service than what is required.

This may be funny example but suppose you went to a beauty salon to get a facial(just simple type of facial) and the person who is performing this work rubs your face for at least 15 to 20 minutes,continously applies all his Tools and techniques only on your face. What will happen? This is as same as in any organisation as well. Activities like conducting more analysis,dismantling a machine without any reason, adjusting its tools,generating more reports than required etc.all are wastes.

7.Defects-The production which is not fit for use is defect.Scrapping the product or reworking may lead to this kind of waste.

Why is Kaizen required?

Under this strategical tool every employee is responsible for identifying the gap and inefficiencies and everyone at each level in organisation will give you suggestions where and how improvements can take place. This tool focuses on improvements and waste reduction productivity effect units etc. Main reasons why every Company/Organisation follows these tools are given below...

1.Helps in improving customer satisfaction- Company will come up with higher quality product with very few faults.

2.Very less waste-Resources are used in such a way so that very less waste is obtained. 

3.Employees' high motivation-Employees at each level contribute and suggest the solutions for the problem which in turn boost their motivation as they play some value to the organisation.

4.Gives target or goals for improvement.

5.Better communication-It removes the bitterness among employees and bring them together which in turn gives more effective results.