Kaizen

Kai Change
Zen For the
better
Kaizen Change for the better refers to
activities that continually improve all functions and involve
all employees
Basic Goals
Discover and Eliminate all Waste in a process
Waste anything that the customer does not pay for
Some waste is necessary or required by law (personnel
files, financial records, meetings, etc.)

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Types of Waste

Overproduction
Waiting
Overprocessing
Inventory
Motion
Defects
Transportation

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Traditional Market scenario

Cost + Profit =
Selling price

Current Market scenario

Selling price - Cost =

Profit
Kaizen Event
Focused effort by a full-time, cross-functional team to analyze and
improve a process in a short time (usually 1 week)

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Kaizen Tools

Flowcharts

Cause and Effect

Diagrams

Value Stream
Mapping

5S

Pareto Charts

Histograms

Takt and Cycle

times

Control charts

Poka Yoke

Scatter Plots

Kanban

Check Sheets

Visual Controls

Statistical Methods

Preventive
Maintenance

5 Whys

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VSM (Value Stream Mapping)
Special type of flow chart that uses symbols
known as
"the Language of Lean" to depict and
improve the flow

Provide optimum value to the customer through a complete

value creation process with minimum waste in:
Design (concept to customer)
Build (order to delivery)
Sustain (in-use through life cycle to service)

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VSM (Example)

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5S

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5S

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5 Whys

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How to use the Kaizen Tools

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Practical keys to Kaizen Success

Standardize your work

easier and safer
Solve problems together
Eliminate waste ask why 5
times
Make everything visual
understanding at a glance
Offer your ideas