Benefits of Kaizen
The origin of the word “Kaizen” comes from Japan. It consists of two words: “Kai,” which means “change,” and “Zen,” which means “good.” So, Kaizen means “good change” or, alternatively, “continuous improvement.” In a manufacturing factory, Kaizen means continuous improvement by involving members of production and production support departments in the practical application of improvement ideas.
Naturally, there are two ways to achieve improvement. One is by investing a huge amount of money to change the situation. The other is by implementing continuous small changes that can impact production and increase productivity.
Kaizen Project Steps
The Kaizen event process involves several steps as outlined below:
01. Identify the problem that needs improvement.
02. Analyze the historical data related to the problem.
03. Find a solution to the problem.
04. Apply the solution in a real-world situation.
05. After implementing the solution, study and analyze its impact.
06. Standardize the solution and monitor it over the long term.
Kaizen Method
To establish a Kaizen project at a production site, the following steps should be taken:
01. Build a team consisting of members from production-related departments such as Industrial Engineering, Planning, Maintenance, Quality Control, and Material Control.
02. Team members should meet weekly to share ideas and discuss implementation strategies.
03. Create a visual board for the Kaizen project to share ideas and track progress.
04. When necessary, seek help from higher authorities to implement the ideas.
Benefits of Kaizen
01. Reduces waste and cost.
02. Improves overall environment, product quality, and customer satisfaction.
03. Increases production line efficiency.
04. Boosts factory income.
05. Develops personal qualities as well as team effort.
In conclusion, the success of a Kaizen project relies heavily on teamwork. It is essential to ensure everyone is seriously involved and committed to completing all tasks on time. Additionally, long-term management support is crucial. The key approach to a successful Kaizen project is to standardize the process for a prolonged period.
