Necessity of Kaizen System for the Industry
Kaizen is a Japanese term that means continuous improvement. Kaizen events are used to make continual improvements throughout a plant at the process or system level. Process improvements are more detailed and take place on the shop floor by the people who are involved in the specific process at hand. The Kaizen event is used to reduce the waste and non-value added steps in order to minimize the time needed to flow through the processes. The system improvements are generally broader in approach and focus on improving the flow through the entire value stream. Normally Kaizen events are done in less than a week, another term Kaizen Blitz is used which means small improvements are made in a short period of time.
Necessity of Kaizen System for the Industry:
Kaizen 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, buttheir implications are far reaching. These can be in the area of Productivity, Quality, Cost, Delivery, Safety & Morale of Employees i.e.; PQCDSM.
- It is continuous process.
Some basic rules should take in to consideration in kaizen System:
Develop a vision of the future. Having defined what is happening now a future state map is created which defines what should be happening if the world was perfect.
- Involve everyone.
- Prepare the group.
- Plan for success.
- Keep the kaizen training to what is actually needed for the event.
- Provide the kaizen training at the right time.
- Properly scale the scope of kaizen event.
- Keep your kaizen goals simple.
- Pick the right lean tool for the job and use it well.
- Go to gemba and stay there the entire week.
- Speak with data.