Kaizen
Kaizen: Often considered to be the building block of all lean production methods, kaizen events are rapid and cost-effective projects that focus on identifying waste, improving productivity, and achieving sustained continual improvement in targeted activities and processes.
Aiming to involve workers from multiple functions and levels in working together to address a problem or improve a process, the kaizen team uses analytical techniques such as value-stream mapping and the 5 Whys to identify opportunities quickly to eliminate waste in a targeted process or production area.
Example: After identifying an area for a rapid improvement event, such as a production area where significant bottlenecks or delays occur, the kaizen team must identify the root cause of the problem. This can be accomplished by utilizing the 5 Whys technique. An example would be:•
Why did the machine stop? There was an overload, and the fuse blew.•
Why was there an overload? The bearing was not sufficiently lubricated.•
Why wasn’t it lubricated sufficiently? The lubrication pump was not pumping sufficiently.•
Why wasn’t it pumping sufficiently? The shaft of the pump was worn and rattling.•
Why was the shaft worn out? There was no strainer attached and metal scrap got in.
Once the root cause of the problem has been identified, the team can then work to collect information on the targeted area, such as measurements of overall product quality, amount of work-in-progress, and scrap rate and source of scrap. Analyzing these data allows the team to identify areas for improvement, and test improvement options before implementation
Aiming to involve workers from multiple functions and levels in working together to address a problem or improve a process, the kaizen team uses analytical techniques such as value-stream mapping and the 5 Whys to identify opportunities quickly to eliminate waste in a targeted process or production area.
Example: After identifying an area for a rapid improvement event, such as a production area where significant bottlenecks or delays occur, the kaizen team must identify the root cause of the problem. This can be accomplished by utilizing the 5 Whys technique. An example would be:•
Why did the machine stop? There was an overload, and the fuse blew.•
Why was there an overload? The bearing was not sufficiently lubricated.•
Why wasn’t it lubricated sufficiently? The lubrication pump was not pumping sufficiently.•
Why wasn’t it pumping sufficiently? The shaft of the pump was worn and rattling.•
Why was the shaft worn out? There was no strainer attached and metal scrap got in.
Once the root cause of the problem has been identified, the team can then work to collect information on the targeted area, such as measurements of overall product quality, amount of work-in-progress, and scrap rate and source of scrap. Analyzing these data allows the team to identify areas for improvement, and test improvement options before implementation
