Kaizen Definition
KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination
What is MUDA?
Muda means any wasteful activity or any obstruction to smooth flow of an activity
Activity = Work + Muda
Expenditure = Cost + waste
That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!
Therefore, Less Muda = More happy clients (as it impacts on quality, cost and delivery of products and services).What is Gemba?
Gemba - Real place - (in our context Work Place)
Gembutsu - tangible objects found at the Gemba
Gemba is where Value Is Added. (The Managers cabin is not a Gemba !)
What is Gemba Kaizen®?
A process of Continuously
Identifying
Reducing
Eliminating
Muda from our Gemba
Some typical misconceptions on Kaizen
Kaizen is for workers; It is not for managers
Kaizen is SMALL improvements only
Kaizen is only a sort of implemented-suggestion scheme
Any implemented improvement is Kaizen
When does it become KAIZEN?
large improvements are made
small time and small money is used
bottleneck problem is attacked
process observation is used
KAIZEN paradigms are deployed
management participation exists
Gemba Kaizen® also Focuses on Mura and Muri
What is Mura?
Mura = Inconsistencies in the system
Happens sometimes?
Happens some places
Happens to some people
One side is ok; the other side is not ok
All this is Mura
What is Muri?
Muri = Physical Strain
Bend to work?
Push hard?
Lift weight?
Repeat tiring action?
Wasteful walk?
All this is Muri
Gemba kaizen®, now redefined …..
A process of Continuously
Identifying
Reducing
Eliminating
Muda, Mura , Muri (3 Mu) from our Gemba
Carrying out GEMBA KAIZEN® Workshops involve:
Focused Improvement
Setting up of Cross-functional teams
A KAIZEN Time slot (4 to 5 days)
Applying 5 golden rules of Gemba management
Avoid spending money (no investment)
Working in PDCA cycle
Five Golden Rules Of Gemba Kaizen® Workshop
1) Go to the Gemba
2) Check Gembutsu - (item at Gemba)
3) Take Temporary Measures on the spot
4) Find root cause & kill
5) Standardize to Prevent Recurrence
PDCA Cycle
Improve what you maintainMaintain what you improve
How to Observe?
Go to the gemba
Do cleaning yourself
Do not sit anywhere
Do not ask for ideas
Look first for Muda
Then look for Mura
Finally look for Muri
5-S
5S is the foundation of Kaizen. All Gemba Kaizen workshop should start by applying the concept of 5S.
Some key benefits of Kaizen
Process Improvement
Observation
Use of new Paradigms
Short time
Zero Investment
Human Development
Profits & Savings
KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination
What is MUDA?
Muda means any wasteful activity or any obstruction to smooth flow of an activity
Activity = Work + Muda
Expenditure = Cost + waste
That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!
Therefore, Less Muda = More happy clients (as it impacts on quality, cost and delivery of products and services).What is Gemba?
Gemba - Real place - (in our context Work Place)
Gembutsu - tangible objects found at the Gemba
Gemba is where Value Is Added. (The Managers cabin is not a Gemba !)
What is Gemba Kaizen®?
A process of Continuously
Identifying
Reducing
Eliminating
Muda from our Gemba
Some typical misconceptions on Kaizen
Kaizen is for workers; It is not for managers
Kaizen is SMALL improvements only
Kaizen is only a sort of implemented-suggestion scheme
Any implemented improvement is Kaizen
When does it become KAIZEN?
large improvements are made
small time and small money is used
bottleneck problem is attacked
process observation is used
KAIZEN paradigms are deployed
management participation exists
Gemba Kaizen® also Focuses on Mura and Muri
What is Mura?
Mura = Inconsistencies in the system
Happens sometimes?
Happens some places
Happens to some people
One side is ok; the other side is not ok
All this is Mura
What is Muri?
Muri = Physical Strain
Bend to work?
Push hard?
Lift weight?
Repeat tiring action?
Wasteful walk?
All this is Muri
Gemba kaizen®, now redefined …..
A process of Continuously
Identifying
Reducing
Eliminating
Muda, Mura , Muri (3 Mu) from our Gemba
Carrying out GEMBA KAIZEN® Workshops involve:
Focused Improvement
Setting up of Cross-functional teams
A KAIZEN Time slot (4 to 5 days)
Applying 5 golden rules of Gemba management
Avoid spending money (no investment)
Working in PDCA cycle
Five Golden Rules Of Gemba Kaizen® Workshop
1) Go to the Gemba
2) Check Gembutsu - (item at Gemba)
3) Take Temporary Measures on the spot
4) Find root cause & kill
5) Standardize to Prevent Recurrence
PDCA Cycle
Improve what you maintainMaintain what you improve
How to Observe?
Go to the gemba
Do cleaning yourself
Do not sit anywhere
Do not ask for ideas
Look first for Muda
Then look for Mura
Finally look for Muri
5-S
5S is the foundation of Kaizen. All Gemba Kaizen workshop should start by applying the concept of 5S.
Some key benefits of Kaizen
Process Improvement
Observation
Use of new Paradigms
Short time
Zero Investment
Human Development
Profits & Savings
