Application of Kaizen System in Textile Industry

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KAIZEN is a Japanese word which consist of two terms i.e.KAI means “CHANGE” and ZEN means “GOOD”. So over all KAIZEN means “Changes done for better improvement in a management system of companies”. In simple manner KAIZEN means continuous improvement by including all members, Higher authorities, Managers, Workers and each and everyone related to it with practical implementation of ideas.

Kaizen refers to a series of activities through which waste sources are eliminated one at a time, for minimal cost, by workers pooling their wisdom and understanding of the work, thus increasing efficiency in an effective timely manner.

The Principles of Kaizen are:

  1. Human resources are the most important company asset
  2. Process must evolve by gradual improvement rather than radical changes
  3. Improvement must be based on evaluation of process performance
  4. By practicing Kaizen culture, managers demonstrate commitment to quality. Also, the workers with adequate support from managers become a major source of improvement.
  5. Kaizen system is simple, buttheir implications are far reaching. These can be in the area of Productivity, Quality, Cost, Delivery, Safety & Morale of Employees i.e.; PQCDSM.
  6. It is continuous process.

Ten basic principles for Improvement in the view of KAIZEN:

  1. Throw outall of your fixed ideas about how to do things.
  2. Think of how the new method willwork-not how it won’t.
  3. Don’t accept excuses. Totally deny the status quo.
  4. Don’t seek perfection. A 50-percent implementation rate is fine as long as it’s done on the spot.
  5. Correct mistakes the moment they’re found.
  6. Don’t spend a lot of money on improvement.
  7. Problems give you a chance to use your brain.
  8. Ask “why” at least five times until you find the ultimate cause.
  9. Ten people’s ideas are better than one person’s.
  10. Improvement knows no limit.

Kaizen activities focus on every operation and process in order to add value and eliminate waste.

Process: is the sequence of operations needed to design and make a product.

Operation: is one activity performed by a single machine or person on that product.



  1. Products(Quantity, Rejects etc.)
  2. Equipment(Changeover, Utilization, Breakdown)
  3. Human(Communication, Awareness, Stillness)
  4. Processes(Waiting Time, Bottleneck, Line Balancing, VCS)
  5. System(QC, Specification, Infection)


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