Kaizen management

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KAIZEN ManagementCharacteristics of

Japanese Production Systems

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Continuous improvement

KAI-ZEN

V:　 Green walking

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What is Industry ?

ProductsServices

Industry

Input Output

Man-powerMachinesMaterialsMethods(4M’s)

TechnologySkill

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Q, C, D

Evaluation of the output ?

Q: QualityC: CostD: Delivery

Industry

Input Output

KAIZENaction

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KAIZEN is a corrective action

KAIZEN is a feedback

Industry

Input Output

KAIZENaction

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KAIZEN is a Japanese word

改 : change 善 : better

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Definition of KAIZEN

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1. A selection of better means or a change of current method for achieving an objective.

The Japan HR Association

Definitions of KAIZEN

2. An accumulation of small changes

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How do farmers pack How do farmers pack oranges?oranges?

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I need help.

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Productivity: 1 net per min.

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Productivity: 5 nets per min. with 2 workers

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Can you think of a better method to pack oranges?

A selection of better means ora change of current method for achieving an objective.

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Productivity: 5 nets per min. with 1 worker

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1. A selection of better means or a change of current method for achieving an objective.


Definitions of KAIZEN

2. An accumulation of small changes

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Chopsticks

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Children hold their chopsticks improperly

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… but still difficult to use

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Soft paddings (Japanese fish paste)

… for some children, balancing the chopsticks is difficult

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Training chopsticks

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KAIZEN is a continuous improvement

Continuous = again and again

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Question

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- I picked up a garbage and put it in a trashcan.

- I wiped the windows and made them clean.

- I used a mop to clean the gasoline left on the floor.

KAIZEN is a small change to make something better.

Where is a division between our jobs and KAIZEN?

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A waitress was working at a restaurant in Tokyo

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A small change of a method (approach)

Any way to pick up the mop?Any way to store the mop?Any way to carry the mop?

KAIZEN is a small change

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toothbrush

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Swatter

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tweezers

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Improvement by changing methods

How do we change methods?

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KAIZEN Steps

KM 39KAIZEN Steps

KM 40KAIZEN Steps Review

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EliminationRemove this sliding door

What is the use of the sliding doors?

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Before After

Why are shoe box doors needed?

1

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Before After

Why is the toilet cover needed?

KM 44ToiletsCDG(Paris) Frankfurt

Hong Kong Tokyo

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Before

After

No sleeves down-jacket is easy to work

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Reduce the number of lights

ReduceA fluorescent light bulb was removed.

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Before

Why two bricks?

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Parking Lot

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AfterBefore

One brick is enough to stop a car

1

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Zebra Zone

1

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Before

After

Side lines of the zebra zone are removed.

1

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Before After

Long or short brush part?

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toothbrushes

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Ribbon waving?

Change

Visual Management

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Pinwheelturns around

Visual Management

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Before

After

The hollow about the key hole smoothes the key movement.

1

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Before

After

To oil the pan, a small teapot is more convenient than a ladle.

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Before

After

Stairways at the railway station should have signs of up and down.

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At JR Kurume StationAt JR Kurume StationAt JR Kurume StationAt JR Kurume Station

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Rush Hour

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Before

After

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Hanging Straps in JR trains

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Hanging strap in Hanging strap in Hong Kong subwaysHong Kong subways


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Suggestion Systemvs.

KAIZEN Suggestion System

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Suggestion SystemYou suggest your ideas, and I will

examine them and implement some of your ideas later.

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Suggestion System Concept

Rew

ard

Idea

Idea

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KAIZEN

sheet

Implemented KAIZEN ideas must be submitted

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Workers’ responsibility

Workers’ responsibility

Management responsibility

Management responsibility

Suggestion System


generation Idea

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Suggestion SystemPropose improvement ideas for any

activity in the company.

KAIZEN Suggestion SystemPropose only improvement ideas which will improve your own work.

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KAIZEN Memo 1

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AOTS KAIZEN

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AOTS KAIZEN

KM 76Reward

For an excellent KAIZEN, a large amount of reward is given (5000 yen, 10000 yen, 50000 yen)

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Award Payment for Each KAIZEN Suggestion (2008)

18

24

110

109

163

83

11

10

0 50 100 150 200

0

1-99

100-299

300-499

500-999

1000-2999

3000-4999

5000+

Jp

n Y

en

Surveyed 528 companies

Average 385 yen

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88.7%1

Implemented suggestions

All suggestions

Among (527) companies,

Total number of employees

Employees who suggested at lease one idea

74.4%

2008

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1. Small change

2. Medium change

3. Big change

(KAIZEN)

(Small group activities)

(Innovation)

--- By individual effort, a better way of proceeding a job is considered. (Idea creation)

--- By group effort, a better way is proposed by following predetermined steps (or rule).

--- By investments in new technology or equipment, dramatic alterations are achieved.

Different styles of change

2

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Process

ChangeTool Change

Tomato Juice

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Nikkei News, Nov. 22,1997

Newspaper Article

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Hydroponics CultivationHydroponics Cultivation

6000 tomatoes6000 tomatoes

1http://www.arigat.net/kandoh.html

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Material

ChangeProcess

ChangeTool Change

Tomato Juice

2

Man-powerMachinesMaterialsMethods

(4M’s)

Industry

Input Output

KAIZENaction

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Breakthrough

Status quo

Management

Staff

Floor people

Two Attitudes

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KAIZEN

Statu

s quo

Innova

tion

KAIZEN

Statu

s quo

Management

Staff

Floor people

Management

Staff

Floor people

Innova

tion

Japanese firms

Non-Japanese firms

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Fin

Kaizen management

Business

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