Kaizen (Continuous Improvement) is a strategy where employees at all levels of a company work together proactively to achieve regular, incremental improvements to the manufacturing process. In a sense, it combines the collective talents within a company to create a powerful engine for improvement. Show
THE DUAL NATURE OF THE KAIZEN SYSTEMKaizen is part action plan and part philosophy.
Kaizen works hand-in-hand with Standardized Work. Standardized Work captures the current best practices for a process, and Kaizen aims to find improvements for those processes. Note the emphasis on current; Standardized Work is living documentation (it continually evolves through Kaizen). Kaizen is part action plan and part philosophy. Consistent application of Kaizen as an action plan develops Kaizen as a philosophy.KAIZEN EVENTSA typical Kaizen event has a process that goes something like this:
This type of Kaizen process cycle is frequently referred to as PDCA (Plan, Do, Check, and Act). PDCA brings a scientific approach to making improvements:
THE KAIZEN PHILOSOPHYInterestingly, Kaizen as an action plan is exactly what develops Kaizen as a philosophy. When Kaizen is applied as an action plan through a consistent and sustained program of successful Kaizen events, it teaches employees to think differently about their work. In other words, consistent application of Kaizen as an action plan creates tremendous long-term value by developing the culture that is needed for truly effective continuous improvement. Kaizen and Six Sigma process are used by industries around the world and, while they both refer to lean principles of eliminating waste, there are distinct differences in how each methodology gets implemented.Related: Japanese companies didn’t earn their reputation for producing high-quality products with maximum efficiency out of nowhere. Their move toward better production standards can be traced back to when the car company Toyota started refining its corporate mindset and business practices in a way that lent itself to the idea of kaizen, or “continuous improvement.” Japan achieved so much success that it led Motorola to develop the Six Sigma lean process as a competing philosophy to keep Western companies from losing market share. Today, you’ll find the Kaizen process and Six Sigma process in wide use in industries around the world. However, while the terms are often used interchangeably to refer to lean principles of eliminating waste, there are distinct differences in how each methodology gets implemented. This guide highlights those distinctions and when you might want to use one or the other. What are the Principles of Kaizen?Companies that decide to follow the Kaizen model must commit to the core principles below. They all tie back to the main idea that there’s always a way to improve things, even if those things seem to function well now.
What Are the Principles of Six Sigma?The core principles of Six Sigma are:
Kaizen vs. Six Sigma: Which One is Better?When it comes to the Lean process, Kaizen and Six Sigma are both offshoots. Kaizen is rooted in the idea that making small, continuous positive changes can lead to significant improvements. As a result, you often find Kaizen put to use in industries like healthcare, but it’s also capable of working at a department level. There are various approaches and tools used to implement Kaizen. For example, you can create value stream mapping (VSM) using Integrify software to document, review, and improve various workflows that produce services and products. Six Sigma process improvement focuses on getting rid of defects and inefficiency in business workflows. It breaks down each process into components and then uses statistics to find weaknesses and areas where an organization can eliminate waste. The goal of Six Sigma is to come up with a way to produce consistent and reliable outcomes. Those who invest in the methodology develop a Six Sigma process map to have a common understanding of a process and the way it works. In addition, lean Six Sigma process mapping helps teams locate complex steps that need simplifying. Another benefit of lean Six Sigma process mapping is comparing a current workflow to a new process. Upon completion, projects teams can share the maps with others to help them understand what’s happening. When to Pick One or the OtherIf you’re looking to improve the whole organization or an entire department, then Kaizen might be the way to go. It allows more flexibility in how you get things accomplished. In addition, there’s no requirement to come up with rigid statistical methodology or other scientific standards. Perfection isn’t the end goal, only gradual improvements. Kaizen also emphasizes getting everyone engaged in making those enhancements. For projects that involve dealing with product defects, Six Sigma may be the better approach. It can eliminate mistakes from the workflow that interfere with the delivery of a final product. In addition, Six Sigma promotes bonding with customers by resolving their issues a top priority. It also removes complications from workflows by applying logic to create a workable and sustainable solution. Get the Right Tool for Your Project MethodologyIntegrify’s workflow platform supports process mapping for any project methodology. That way, you can quickly develop workable solutions to address your business needs. Set up a demo of our software by contacting us here. Is Kaizen the same as just in time?Just-in-time production encourages every employee to analyze current processes and offer suggestions for improvement. Widely known as Kaizen, this never-ending cycle will allow any team to constantly improve its performance and “change for the better”.
Is Kaizen the same as lean?Kaizen and Lean Are Not Short Term Fixes
Lean is focused on eliminating waste, and increasing productivity and value adds for the consumer while Kaizen focuses on continuous improvement. This transformation is not a short term fix for the problem of the day.
Is Kaizen the same as 5S?While Kaizen is a general approach to improvement, 5S is a way to lay the groundwork for improvement. The two go hand in hand with 5S being part of the Kaizen system and lean manufacturing.
Is Kaizen similar to Six Sigma?Six Sigma aims for perfection, or zero defects, as often as possible, while Kaizen aims to continuously improve the overall work environment, the systems in place and the strategies used without focusing on percentile success rates.
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