What is Kaizen ?

Kaizen is a word with meaning ‘a change for better’. So, any change which gives better results than previous state or situation can be called as Kaizen. But there are some characteristics for a change to be called as Kaizen. These characteristics gives the this word most popular and valuable.

Characteristics of a Kaizen

1. Change is small
2. Easily implementable
3. Some new idea will be there which leads to change
4. Low Investment

Basics of Kaizen

Any situation or a state is not perfect, and it can be improved. Even if a situation or a state is reached after a Kaizen. There is always a scope for improvement. This is the basics of Kaizen and every one in an organisation should know this and should try and implement Kaizen. So I am once again pointing out the basics of kaizen;

1. There is always a scope for improvement
2. Involvement of every one

How Kaizen save money ?

If we talk about a manufacturing industry Kaizen results in reduction in the defects, improvement in the safety, increase in output, reduction in the raw material, reduction in the waiting time, reduction in inventory, reduction in motion, etc. In general it will eliminate the wastes. What will happens if we eliminate the waste?. Definitely it will saves money.

Please note that one or two Kaizen may not enough for getting a good savings, but a large no of kaizens, from all department, will leads to a good savings. Now a days your customers will also evaluate you, by checking whether you have implemented Kaizen drive in your organisation. Because they know that it will reduce the manufacturing cost.

Let’s conclude this article after some Kaizen examples

Example 1

In a weaving machine the threads are loaded in to the machine as spools and it is loaded at the back of the machine. And operator was not able to see the spool and he was not able to see whether the spool is going to finish or not, for taking the timely actions. This situation was causing defects when when the thread in the spool finishes and operator runs the machines. It will results in the rework and output will decrease. And in one day the operator of a machine got an idea to put a mirror so as to he can saw the spool all the time. 👍

Example 2

An old soap factory. Soaps come in a conveyor. It is a packing station. The operator at the packing station packs the soap and place it in the conveyor. Due to low cycle time and frequent packing operation operator at the packing stations forgot to place the soap in the cover and he places the empty pack in the conveyor in folded position No one can identify this defect and it will result in customer complaint. And one day the operator got an idea to place a pedestal fan to the conveyor. And now what happens is, now empty packets come in the conveyor, it flew away due to the air flow from the fan. 😃

Example 3

In an office every time employees for got to switch of the AC. One day office boy got an idea to fix some ribbons at the air vent of the ac. Now what happens is when the ac is on every one can see the dancing of the ribbon and switch of the ac when not needed.😜

Example 4

In my home, we was not able to sleep properly due to mosquitoes. One day I closed all windows and ventilators with a net. So that a single mosquito cannot enter my house. And now 😴😴😴

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