Kaizen is a method of improving business operations and decreasing waste. The word Kaizen is derived from the Japanese word Kai meaning Change and Zen meaning good, it means “continuous ongoing improvement” or “change for the better”.
The main objective of Kaizen is continuously improving a system, regardless of its size and complexity. It is also called problem-solving, and people oriented. It is a very efficient and effective technique for manufacturing operations in the food industry. It is the “building block” of all lean production methods.
Kaizen is a very important tool for the improvement of performance in manufacturing and the non-manufacturing situation quickly without huge capital investments or extensive commitments of employee time.
1. Method and implementation
Kaizen takes place to resolve specific problems. Kaizen is the method used to make small changes or improvements continually that involve processes to reduce waste.
5 S is the system to reduce waste and optimize productivity by maintaining an orderly workplace and providing a methodology for organizing, cleaning, developing, and sustaining a productive work environment.
There are two types of waste:
· Pure waste - Action that could be stopped without affecting the customer
· Incidental waste – Action that needs to be done based on how the current system operates
but does not add value.
The goal of Kaizen is to eliminate or improve steps that do not add value and involve the workers from multiple functions and levels in the organization in working together to address the problem or to improve the process.
Kaizen is the manufacturing technique that is adopted by forward-looking manufacturing companies where employees form teams at various levels. It encourages all employees to make improvements and modify production activities through the continuous improvement of manufacturing processes
5 S Method
· Seiri (Sort) - Organize
· Seiso (Shine)- Cleanliness
· Seition (Set of order) - Orderliness
· Seiketsu (Standardize)
· Shitsuke (Sustain)- Discipline
1.1. Sort
This method distinguishes the needed item from unneeded items and eliminates the latter. An effective visual method to identify these unneeded items is called “red tagging”. Once red-tag items are identified, these items are moved to a central holding area for subsequent disposal, recycling, or reassignment.
1.2. Shine
Once the clutter clogging the work area is distinguished and eliminated, and the remaining items are organized, daily follow-up cleaning is necessary to sustain this improvement.
1.3. Set of order
The set of orders focuses on creating efficient and effective storage methods to arrange items. It means setting the items in an arranged and organized way, along with this it includes painting the floor, affixing labels, and installing modular shelving and cabinets.
1.4. Standardize
Once all the 3 pillars are done, this step ensures that the items are clean including prevention – preventing the accumulation of unpeeled items, preventing procedures from breaking down, and preventing equipment and materials from getting dirty.
1.5. Sustain
Sustain is the habit of properly maintaining the correct procedures. It is the most difficult pillar to implement. It focuses on a new status and standard of workplace organization. Without sustaining pillars, the outcome and achievement of other pillars do not last long.
The kaizen manufacturing technique consists of various continuous improvement activities also known as the Kaizen umbrella.
2. Benefits of Kaizen
The main goal of Kaizen is to improve productivity, effectiveness, and safety.
There are several benefits of Kaizen technology, including:
· Forming teamwork – Guides employees and serves as a problem-solving approach.
· Continuous improvement – improves quality, safety, cost structures, delivery, environments,
customer service, and satisfaction.
· Widely applicable – This is widely used in various food industries.
· Reduces waste – Kaizen is used to reduce waste
· Customer satisfaction – Empowers employees, enriches the work experience, and brings out
the best in every person.
3. Use of PDCA Cycle to support Kaizen
The PDCA cycle is an effective approach to solving problems and managing change. PDCA Cycle consists of four components:
3.1 Plan – In case of any problem, first identify the problem, collect relevant data, understand the
problem’s root cause, develop a hypothesis about what the issue may be, and decide which
one to resolve first.
3.2 Do – After finalizing the problem, develop and implement a solution, decide upon a
measurement to gauge its effectiveness, and decide whether the hypothesis is supported or
not.
3.3 Check – Confirm and compare the result before and after data comparison. Study the result
and identify a suitable solution.
3.4 Act – Act means to finalize and implement the best solution.
4. Reference
· https://hal.archives-ouvertes.fr/hal-03391087/document
· https://www.epa.gov/sustainability/lean-thinking-and-methods-5s
· https://online.kettering.edu/news/2017/01/05/how-kaizen-and-lean-manufacturing-work-
together
· https://www.graphicproducts.com/articles/kaizen-benefits/
· https://www.mindtools.com/pages/article/newSTR_97.htm
· https://theleanway.net/the-continuous-improvement-cycle-pdca
· https://www.mindtools.com/pages/article/newPPM_89.htm
· https://betterprocesssolutions.com/2020/08/19/what-are-the-three-pillars-of-kaizen/
· https://betterprocesssolutions.com/2020/08/19/what-are-the-three-pillars-of-kaizen/
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