KAIZEN

What is “ KAIZEN “ ?

Its Japanese means Improvement

/ make better.

What are the Targets ?

A. Quality of Products
B. Quality of Equipment
C. Quality of Processes
D. Quality of Human
E. Quality of System

Examples as Target ｓ & KAIZEN

A. Case of Product
Exp.
Reduce No. of Defects, or Rejects
by perfect inspection system

　　note: Zero Defects

Not ex post action, but preventive
action should be taken

B. Case of Equipment
Exp.
a. Prevent machine from Breakdown by
daily inspection and oiling, etc.
b. Operate machines in optimal conditions
to achieve designed production capacity
c. Reduce the loss time caused by
preparation and setup

C. Case of Process
Exp.
a. Improve Line Balance to remove
the bottle-neck among processes
by Multi-handling works
b. Reduce the waiting time among
 processes
c. Avoid mistakes by Visual Control
such as KANBAN

D. Case of Human

Exp.
a. Awareness on Quality & Productivity
b. Consciousness on the surrounding
problems
c. Mutual communication to have
cooperation and common information
d. Competitive effort to produce each
idea

E. Case of System

Exp.
a. Organization
　　 QC Section related to production
department should be functionally
effective
b. Manuals
Operational, Inspectional, etc.
c. Document
Specification, ISO, etc.

Steps of KAIZEN Process

Step-1 Brain Storming

Step-2 Theme and Goal Set-up
Step-3 Data Collection
Step-4 Classification
Step-5 Cause and Effect Analysis
Step-6 Countermeasure Set-up （Plan)
Step-7 Implementation (Do)
Step-8 Effectiveness of Results (Check)
Step-9 Correction of Countermeasure (Action)
Step-10 Monitoring
Step-11 Standardization
Step-1. Brain Storming

A. 5 W 1 H
1. What 2. When 3. Where 4. Who 5. Why
1. How

B. 4 M
1. Man 2. Machine 3. Method 4. Material

C. 3 Mu
1. Muri (Strain) 2. Muda (Waste)
3. Mura (Irregularity)

5W1H

What is done ?
What is being done ?
What is the best to do ?
Isn’t there anyone who commits something
about the 3 MUs ?
How about other 4 W and 1 H ?

４ Ms

a. Man
1) Does everyone observe the standards ?
2) Is the working efficiency satisfactory ?
3) Does everyone have problem-consciousness ?
4) Does everyone have a strong sense of responsibility ?
5) Does everyone acquire experience ?

b. Machine
1) Does every machine meet the production capacity ?
2) Is checking carried out thoroughly ?
3) Is there any unusual noise produced ?

c. Materials
1) Are there errors in quantity ?
2) Are there errors in raw materials ?
3) Is the total stock proper ?
 4) Is there a waste of materials ?
5) Are the goods in process neglected ?

d. Method
1) Are the operational manuals clear ?
2) Are the setups all right ?
3) Is the air conditioning adequate ?
4) Is the lighting adequate ?

３ Mu（Muda, Muri, Mura）

Is there any Waste, Strain, Irregularity ?

　　　　　　　　　　　　　　　 in man ?
in skill
in method
in time
in machine
in jigs and tools
in materials
in production
in stock

Step-2. Theme and Goal Set-up

A. Selection of Theme
Compare the significance of errors from effectiveness point of view when it is
improved

B. Goal Set-up
Measure the Status quo as Benchmark and set up a high goal

Step-3. Data Collection

A. Categorize the vital items to be

collected in check sheets

B. Take data by using Check Sheets

for records

note: Record, or Inspection type is

selected to meet the purpose
Check Sheet for Records

It is used to count No. of defects, or to know

the kind of dispersion
Exp.
a. Check Sheet related to items of error
b. Check Sheet related to factors of wrong
c. Check Sheet related to dispersion in process
d. Check Sheet related to positions of defect

Check Sheet for Inspection

　　　　　 It is used to inspect important items such as

operational conditions, and security
　　　　 Exp.
　　a. Check Sheet related to equipment
　　 b. Check Sheet related to operations
　　c. Check Sheet related to startup & finish

　　　 Points to make Check Sheet

　　　a. Setup of kinds and clearness on targets
　　　b. Avoid overlook on important items by personal
　　　 experience and the past data
　　　 c. Classify items for the analysis after processes

Step-4. Classification

Pareto Diagram is used to select the major items and identify the rate

Several items will be targeted to achieve

more than 70 % ~ 90 % of improvement

Step-5. Cause & Effect Analysis

a. Collect/Discuss probable items as the

causes to targeted effect and classify
them according to 4 M
b. Select highly probable items and
discuss the details
 c. Identify some items as the main causes

Step-6. Countermeasure Set-up

A. Human errors
　 a. Causes of Error
Exp. Careless Ignorance Disregard
Caution ! “Chronic Type”

　 ｂ. Approach
An opposite action will be effective as
　 the countermeasure
　 Exp. Don’t do it like that !
　 Educate operators on Shitsuke !

B. Technical Errors

a. Causes of Error ”Sporadic Type”

Exp. Deterioration
Operation out of Optimal Condition

　　　　　　　　　　　　　　　　　　　　　　　　　
b. Approach
(Easy Error)
A minor change by QC 7 tools
will be the countermeasure
(Difficult Error)
Review the functions and principle of Processes
and Machines
It would have to be logically solved by reaching after
intrinsic Physical Mechanism causing Phenomena