Kaizen Definition:
The word “Kai” means change and “Zen” mean Better. Thereby the word Kaizen means Change for Betterment or in simply “Improvement”. 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 (3Mu) 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
- Go to the Gemba
- Check Gembutsu – (item at Gemba)
- Take Temporary Measures on the spot
- Find root cause & kill
- Standardize to Prevent Recurrence
