Kaizen

Kaizen is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. Kaizen was created in Japan following World War II. The word Kaizen means "continuous improvement". It comes from the Japanese words "Kai" meaning school and "Zen" meaning wisdom.

 Kaizen is a system that involves every employee - from upper management to the cleaning crew. Everyone is encouraged to come up with small improvement suggestions on a regular basis. This is not a once a month or once a year activity. It is continuous. In most cases these are not ideas for major changes. Kaizen is based on making little changes on a regular basis: always improving productivity, safety and effectiveness while reducing waste.

 Suggestions are not limited to a specific area such as production or marketing. Kaizen is based on making changes anywhere that improvements can be made. " The Kaizen philosophy is to "do it better, make it better, improve it even if it isn't broken, because if we don't, we can't compete with those who do."

Standardised work Implement solution Make problems visible

KAIZEN OR CONTINUOUS IMPROVEMENTS

Test hypothesis
Develop counter measure

Hypothesize solution

Determine root causes

 Improvements are usually accomplished at little or no expense, without sophisticated techniques or expensive equipments. It focuses on simplification by breaking down complex processes into their sub-processes and then improving them. Kaizen relies heavily on a culture that encourages suggestions by operators who continually try to incrementally improve their job or process.

 It is the process of continuous improvement in small increments that make the process more efficient, effective, under control, and adaptable. Outside every production unit there are display boards that display small improvements made in the machines that have helped improve productivity, speed, reduced workers load etc. the kaizen also mentions the name of the employee who suggested it.

Qulaity circles
Quality Circle is a small group of 6 to 12 employees doing similar work who voluntarily meet together on a regular basis to identify improvements in their respective work areas. PHILOSOPHY Quality Circle is a people building philosophy, which provides self motivation and improves work environment. It represents a philosophy of managing people specially those at the grass root level.

 CONCEPT The concept of Quality Circle is primarily based upon recognition of value of the worker as a human being, as someone who willingly put efforts to improve the job, his wisdom, intelligence, experience, attitude and feelings. OBJECTIVE The objectives of Quality Circles are multi-faced Change in attitude; self development; development of team spirit, improvement in organizational culture

 The launching of Quality Circles involves the following steps:

Expose middle level executives to the concept. Explain the concept to the employees and invite them to volunteer as members of Quality Circles. Nominate senior officers as facilitators. Form a steering committee. Arrange trainings A meeting should be fixed preferably one hour a week for the Quality Circle to meet. Formally inaugurate the circle. Arrange necessary facilities for the Quality Circle meeting and its operation.

 . BASIC PROBLEM SOLVING TECHNIQUES The following techniques are most commonly used to analyze and solve work related problems. 1. Brain storming. 2. Pareto Diagrams. 3. Ishikawa diagram(Fishbone diagram). 4. Cause & Effect Analysis. 5. Data Collection. 6. Data Analysis.

The tools used for data analysis are: 1. Tables. 2. Bar Charts. 3. Histograms. 4. Circle graphs. 5. Line graphs. 6. Scattergrams. 7. Control Charts

Objectives of Quality Circles

Promote job involvement Create problem solving capability Improve communication Promote leadership qualities Promote personal development Develop a greater awareness for cleanliness Develop greater awareness for safety

 Improve morale through closer identity of employee objectives with organization's objectives Reduce errors. Enhance quality Inspire more effective team work Build an attitude of problem prevention Promote cost reduction Develop harmonious manager, supervisor and worker relationship Improve productivity Reduce downtime of machines and equipment Increase employee motivation