Kaizen

Kaizen

Organisations that use Kaizen report productivity increases of greater than 30%, a 50% reduction in the floor space required with a smaller crew size. In addition, some report as much as a 50% improvement in inventory accuracy while reducing their inventory levels.

What is Kaizen?

Kaizen is the Japanese name for continuous improvement. The word was made popular in the west by a book of the same name written by Masaaki Imai and is now widely used and understood. Kaizen is an approach to creating continuous improvement based on the idea that small, ongoing positive changes can reap significant improvements. When done properly, a company can cut costs, improve safety, quality and employee engagement, thus helping every aspect of the company.
A Kaizen event is not just a training session or workshop therefore all team members need to be prepared to do whatever is necessary to make their team successful. This may include cleaning, painting, or moving materials and equipment. A Kaizen event usually takes 3 to 5 days and involves employees directly impacted by the changes (operations, maintenance, quality, etc) manager/supervisor responsible for the process, and someone from outside the team who can often identify potential issues that would otherwise be overlooked. The teams are led by the team leader, who is responsible for the work rules within the team. However, every team member is expected to be fully focused on the team’s efforts. With a bias toward action, this group activity is meant to make rapid change. This is a focused and finite attack on a particular problem or opportunity for improvement.

The Team’s Engagement Provides Expertise and Builds Commitment!

Kaizen is also a good way to build a team between employees who would not normally work together. An example like a planner or buyer would be brought in on the shop floor to help run one of the kaizen teams. This employee may have little manufacturing experience, but the process of the kaizen allows for that. These “fresh eyes” from other departments now know the pains and struggles an operator goes through on a daily basis. After the event, there is now a closer understanding of what “actually” happens versus what was “supposed” to happen. This is a great tool for bridging the gap between the “shop floor and upstairs office battle” we all know and love.

For further information on Kaizen please contact and I will be more than happy to get back to you.