Tag: pdca

Kaizen

Kaizen – Change for better

Kaizen is the Japanese word for “Improvement”. The literal translation is “Change for Better”.

Within Lean is often referred to as Continuous Improvement, even though this is not in the literal translation is implied in its use. Continuous Improvement is one of the two base pillars of Lean, the other being respect for people (or respect for humanity).

The process of Kaizen is built around the philosophy that you should always strive to better yourself or better the processes of your business. Eliminating waste is the main focus of Kaizen and it is beneficial for both the workers and the company. One should always strive to root out waste and make daily improvements. The big improvements may be impressive, but the small improvements add up over time and make a culture of improvement present within all layers of the company. Each time an improvement is made it becomes deeper engrained in the culture of the company.

Exactly how these improvements are made differ through many different tools and methods. In the workplace the method of 5S is common to organize and set in order for an efficient work environment. When it comes to more advanced improvements it is common to work within the framework of PDCA (Plan, Do, Check and Act).

No matter how you go about it you should always document the improvements made, this is important not only for benchmarking but also to learn and fully understand what has been done and why. Also, it is a great help if you are to spread a particular solution to other parts of the business. Due to the documentation some companies refer to form where you document your improvements as Kaizen and they are sometimes divided into different levels depending on the size of the improvement.




Where would I begin today?

I am, as you might have guessed, partway on my journey. So far I have experienced and tried some of the tools of Lean and I have tried my best to live the philosophy of continuous improvement and respect for people (or humanity). My way has been anything but straight and it has taken me longer than I feel it should to get where I am today. But if I where to start again today, where would I start?

I have given this a lot of thought and there are a lot of choices. One way I know many do start is through 5S and it is really the first real hands on contact I had with Lean. But I am not convinced this is the best way to get started.

Setting things in order is always a good thing, but from what I remember the problem for me was that there was no depth to the thinking, and thus it was a bit of a waste. Since understanding was not there it was almost insurmountable to actually maintain this order.

Where I think I would start is with PDCA (Plan-Do-Check Act). It is a beautiful way to do anything and it will give you guidance through having a proper plan, by carrying through and analyse the results, comparing them to what was expected. With this you learn to see a new dimension of what you have done or are about to do. Most important , you can actually turn any situation to a valuable lesson. No matter if you have succeeded or failed there is always something to be learned. Through PDCA you have a framework for this.

With this said, my next step from PDCA would be 5S but done with a proper PDCA dimension. Before you start to remove anything. Make sure you have the full picture. In a factory it might not be as easy as just removing things and put them into a red tag quarantine area. If you remove things used by others but not yourself you are not being respectful and you are not being efficient. This will result in things being removed and returned and maybe removed again. This will be pure waste. Also it will make coworkers to distrust the tool. Doing informed work will get the respect of coworkers and be appreciated by most. Now, I am not saying there should be no red tag area but I am saying it should be used when the team decides and not when a single operator decides so.