What the heck is Kaizen?
Kaizen is a Japanese word meaning “good change.” This word has become synonymous with process improvement and streamlining. As one of the main tenants of the Toyota Production System (TPS), most manufacturers seek to utilize Kaizen. The core idea is to find and make positive changes continuously. Different companies implement this idea in different practices, but the core philosophy remains the same: never stop improving your processes. Today we are going to talk about how it can be implemented, and some of the misunderstandings that can arise.
Background:
Like many of the Toyota Production System buzz words, they stem from Edward Demming’s statistical approach to manufacturing quality in the 1940’s. A rebuilding Japan embraced these ideals and proved the power of this approach. The Toyota Production System coined many phrases for individual practices or philosophies, and is considered the gold standard. During my time in automotive manufacturing, everyone wanted to implement the TPS.
What is Kaizen:
At the core level, Kaizen is just a theory of continuous improvement (CI). Find an issue, improve it, verify it was fixed, now find the next issue. While originally focused on production quality, it can impact all facets of a factory. Employee safety is one such realm where the Kaizen ethos has led to much safer work places. Kaizen is also meant to be practiced by everyone. CEOs need to have the same improvement mind set as the rest of the employees to maximize effectiveness. In that way, it often leads to better connected companies, building moral and trust in leadership.
How is Kaizen Implemented:
There are several ways to implement Kaizen, and the most popular aren’t always the best. Some of the more common strategies are:
Kaizen Events – These are one-time events held to engage a wider team and search for improvements. At the end an action item list is generated and distributed, based on what the team found. The largest pro of this method is, since it is only a one-time meeting, a bigger group can be engaged. The short duration also leads to the largest con; no time for action, and no time for fix validation. These are best viewed as a companies’ introduction to continuous improvement. It gets a lot of people thinking, and with proper follow-up, can be a great first step. Otherwise, it can lead to a bunch of back patting, but no tangible change.
Continuous Improvement Boards – The CI Board is a misunderstood practice which can be one of the most effective practice when implemented effectively. The idea is that a board is affixed in a central location, and all employees can add tickets to it for areas of improvement. Once a ticket is created and posted, it is assigned to an owner. A set, recurring meeting is held to review the board and items, including following up on old items. One of the main failure modes for a CI board is inadequate filtering. If junk tickets are often posted, and actioned, then great ideas are missed. Also, a culture of not taking it seriously can lead to major missed opportunities. When done correctly, however, this can revolutionize a manufacturing company.
Production Walks – Everyone knows you have to get out and walk to manage production, and a daily scheduled walk with a large group is a great way to scout for improvement opportunities. These walks are incredibly powerful, so long as the team is focused on improvement. The walk doesn’t have to take a long time and should be accompanied by a short meeting to discuss findings. The biggest issue is usually team members losing focus and becoming numb to certain problems after seeing them every day. Keeping a fresh outlook and motivated team is essential.
Conclusion:
Kaizen, or continuous improvement, is a core tenant of any growing, successful company. No process is perfect, and only hubris would lead a team to think they couldn’t improve. Here at MFG Concepts, we have seen it all from companies that embrace CI to a fault, to those who fear change. We pride ourselves in striking the perfect middle ground when bringing Kaizen to our clients. Contact us today and let us help you improve every day!
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