KAIZEN :

KAI = CONTINUOUS
ZEN = IMPROVEMENT
Kaizen = Continuous Improvement
KAIZEN:
Japanese term, often translated as ongoing, continuous improvement, is the strategy for
making continuous improvements in all functions of an organization. It focuses on
improving the process rather than achieving certain results.
Continuous improvement involving everyone in the Company is the foundation of Japanese
Business success. They have proved that Manufacturing Excellence comes from Continuous
Efforts by Everyone to Improve their Jobs and surroundings.

BRIEF HISTORY

Japanese term, often translated as ongoing, continuous improvement

Developed IN World War II
America was brought in to help rebuild Japan
William Edwards Demming known as father of Kaizen for actuality introducing and
teaching Kaizen

EVERYTHING IS CHANGING
In todays competitiveness, Government rules are changing, customers expectations are
changing, product designs are changing, product quality is changing, almost everything is
changing.
For survival and to remain competitive we also need to change.

WE MUST CHANGE

a. Our way of thinking

b. Our way of doing job
IF WE DO NOT CHANGE OURSELVES WE WILL NOT MOVE FORWARD BUT WE WILL MOVE
BACKWARD.

THE HUMAN BEING

a. We have the ability to think

b. We have the ability to decide
c. We have the ability to protect ourselves
d. We have the ability to utilize our mind
Had we not been able to think. No Human Being would have been able to survive on the
Earth. It is our endless ability to think which has enabled us to survive and thrive on the
earth.

PROCESS OF KAIZEN

a. Small-small improvements
b. Happens continuously
c. Provides gradual change
d. Everybody can participate
e. Requires minimum investment
f. Resources are own people
g. Everyone in the Organization can do Kaizen

WHEN DO WE DO KAIZEN

a. Whenever there is a problem

b. Whenever there is an opportunity
c. Whenever there is a gap between;
What it is now?
What it should be?
What it could be?

5 W & 2 H Formula

1. What Is Wrong
Is Causing the Problem
2. When? Does it Happen

3. Where? Is the Problem (Location).

4. Who? Does it
Is Responsible for doing it
5. Why? Does it happen
Does he do it this way

1. How Else could it be done

Do we improve the situation
 Seven Steps of Kaizen

1. Identification of the problem

2. Analysis (5 Whys)
3. Target setting (Quality, Delivery, cost)
4. Discussions (5 W & 2H Formula)
5. Research (Benefit, problems in implementation)
6. Implementation (Practically)
7. Documentation etc. (Filling of Kaizen sheet)

AREAS OF KAIZEN :
1. Quality
2. Cost
3. Safety
4. Energy
5. Environment
6. Maintenance
7. Housekeeping
8. Operations
9. Productivity
10. Morale
11. Delivery

IMPORTANCE OF KAIZEN

1. It helps in decreasing the waste in areas such as inventory, transportation and over
production etc.
2. It focuses on creative investments and small improvements instead of large capital
investments and thus provide immediate result.
3. Makes the job easier, simpler, safer & faster
4. Increases efficiency
5. Improves the Moral of the Employees
6. Improves Quality
7. Overall improvement of the Organization
8. Happier Customer

WAYS TO CREATE KAIZEN CULTURE

a. Success breeds success - create small -small Iceland's of successes

b. Be proactive
c. Be patient.
d. Be honest with your mistakes
e. Do not criticize anyone
f. Do not be complacent with present status
g. Dont hide problems
h. Dont hesitate to take help from others
i. Do it now, make it your habit
j. Dont give up
k. Promote Teamwork
l. Appreciate others wherever deserved
m. Take Groups consensus before implementing
n. Find out what is wrong and not who is wrong
o. Be flexible not rigid
p. Focus on Training
q. More emphasis on Systems
r. Give suggestions when required
s. Take advice from expert, if needed
t. Have respect for individuals
u. Always Standardize the change