Kaizen Theory

Kaizen theory

it is a Japanese theory in which slow but continuous improvement of system is the key principle.

• kaizen is the base of Lean manufacturing and Toyota manufacturing system.
•  In an Assembly line/work station that uses kaizen, all workers look for small ways to improve work processes in a regular manner. after a long time, these small changes make a big difference in the product quality and for the organization.
• In this process approx zero defect products are found at the final stage because all defective parts are removed during the process.
• It is very important to achieve six sigma quality control.
• it is not a brainstorming process

For example: suppose that there are three work station and if the component at work station is defective then it will be removed at the same time it will not be sent to the next station.

So Finally, we get defects free products.

Problem-solving process

• Employees participation- 

Seek the participation of employees, how can they involve in the improvement of products. Open a discussion forum for employee to present their thought freely. If any improvement found then it must be considered.

• Problems identification-

It may be found in a different way like problem box, directly contact with the respective higher department, feedback from all employees, gather a list of problems and potential opportunities. Create a shortlist according to the priority if there are many issues.

• Solution generation-

Encourage employees to offer creative solutions, with any type of ideas encouraged. to do so the company/industry can offer prizes to encourage them.

• Selection of best solution- 

apply all the incoming suggested solution either on paper or practically. 

"Remember that any suggested solution will not be underestimated." 

Implement the winning solution in the final process chosen above.

• Result Analysis from obtaining data-

At various intervals, observe the progress, with specific plans and obtain some data form that process this work will be done by respective workers.

Determine how successful the change has been.

• Standardization through the org- 

If results are positive, adopt the solution throughout the organization. 
Try to award that employee who gave that idea it will encourage them to find the best solution

• Repeat- 

These seven steps should be repeated on an ongoing basis, with new solutions tested where appropriate or new lists of problems tackled.