Kaizen

Technical Education

7/18/2024

Kaizen

Transcript

00:00The word kaizen in Japanese can actually be broken down into two separate words, where

00:27k equals change and zen equals good, simply meaning change for better. In English, kaizen

00:37is typically applied for implementing continuous improvement.

00:43Kaizen is an approach to activity organisation based on common sense, self-discipline, order

00:49and economy. The kaizen method is a strong contributor and fundamental part of a lean

00:56production process model in lean manufacturing. It also applies to lean software development.

01:07The history of kaizen begins after World War 2, when Toyota first implemented quality cycles

01:13in its production processes. This was influenced in part by American business and quality management

01:18teachers who visited the country. Masakai Imai is a Japanese organisational theorist

01:25and management consultant, known for his work on quality management, specifically on

01:31kaizen. In 1985, he founded the Kaizen Institute Consulting Group.

01:39The kaizen methods follow ten specific principles, which are described below.

01:441. Improve everything continuously. 2. Abolish old, traditional concepts.

01:513. Accept no excuses and make things happen. 4. Say no to the status quo of implementing

01:59new methods and assuming they will work. 5. If something is wrong, correct it.

02:106. Empower everyone to take part in problem solving.

02:157. Get information and opinions from multiple people.

02:198. Before making decisions, ask why five times to get to the root cause.

02:269. Be economical. Save money through small improvements,

02:30and spend the money saved on further improvements.

02:3310. Remember that improvement has no limits. Never stop trying to improve.

02:42Here we see the questions that should be asked, as in Principle 8.

02:47The five W's and one H of kaizen. The who, what, where, when, and why, as well as the how.

02:56The kaizen method strives towards perfection by eliminating waste, muda, in the workplace.

03:03The goal of kaizen is production without wastes by improving standardized activities and processes.

03:10Industrialization is a process of eliminating waste, muda, in the workplace.

03:15The goal of kaizen is production without wastes by improving standardized activities and processes.

03:21Industrial engineer, Taichi Ono, the father of the Toyota production system,

03:26noticed that there was an 80% loss in every process, and the value of the process is less than 20%.

03:37After analyzing manufacturing processes,

03:39Taichi Ono was able to identify which steps add value and which ones do not.

03:45As a result, he developed a better way for organizations to identify

03:49waste with his 7-waste model. These wastes include...

03:541. Delay. Waiting or time spent in a queue with no value being added.

04:00A large part of an individual product's life is spent waiting to be worked on.

04:052. Producing more than you need. Overproduction usually hides and or generates all the others.

04:13It leads to excessive inventory, which then requires the expenditure of time and effort.

04:193. Overprocessing or undertaking non-value-added activity.

04:31Overprocessing occurs when more work is performed on a piece than what's required by the customer.

04:414. Transportation. Each time a product is moved,

04:45it stands the risk of being damaged, lost, delayed, etc., as well as being a cost for no added value.

04:525. Unnecessary movement or motion. Motion refers to the damage that the

04:57production process inflicts on the entity that creates the product. This may be over time,

05:03wear and tear for equipment, and repetitive strain injuries for the workers, or,

05:07during discrete events, accidents that damage equipment and or injure workers.

05:136. Inventory. Whether it's in the form of raw materials, work in progress, or finished goods,

05:20represent a capital outlay that has not yet produced an income, either by the producer

05:26or for the consumer. 7. Production of defects.

05:31Defects cause extra cost for reworking the part,

05:35and can sometimes result in doubling the cost of one single product.

05:42you

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