{"id":22173,"date":"2021-11-18T10:28:32","date_gmt":"2021-11-18T10:28:32","guid":{"rendered":"https:\/\/www.manutan.co.uk\/blog\/?p=22173"},"modified":"2023-03-14T15:27:45","modified_gmt":"2023-03-14T15:27:45","slug":"kaizen-method-how-to-continuously-improve-your-companys-performance","status":"publish","type":"post","link":"https:\/\/www.manutan.co.uk\/blog\/productivity\/kaizen-method-how-to-continuously-improve-your-companys-performance\/","title":{"rendered":"Kaizen method: how to continuously improve your company\u2019s performance"},"content":{"rendered":"

Lean Six Sigma<\/a> is a method of continuous improvement that involves all actors in a process to eliminate waste, i.e. anything that reduces the efficiency and performance of a production unit or the entire company. <\/span>\u00a0<\/span><\/p>\n

This approach is based on another work optimisation method: the Kaizen system. Originating in Japan, it is now successfully used worldwide by many companies in all sectors. So, what is the Kaizen method? What are its advantages and how can you implement it? This article provides the answers to all these questions.<\/span>\u00a0<\/span><\/p>\n

Definition: <\/span>W<\/span>hat is the Kaizen method?<\/span><\/h2>\n

A fusion of the Japanese words \u201ckai\u201d and \u201czen\u201d (meaning \u201cchange\u201d and \u201cgood\u201d respectively), the Kaizen method focuses on the continuous improvement of company performance as well as the optimisation of employees\u2019 time and working conditions. <\/span>\u00a0<\/span><\/p>\n

The implementation of abrupt changes in management systems can be a psychological hindrance for many employees. The Kaizen method instead consists of a multitude of tools and small, simple, concrete and inexpensive tasks to help achieve the set objectives.<\/span>\u00a0<\/span><\/p>\n

What we ask employees is simply that they ask themselves questions: \u201cWhy am I doing this?\u201d, \u201cWhat are my customer\u2019s needs?\u201d, \u201cHow can I improve my process and meet their needs in a simple and efficient way?\u201d.<\/span>\u00a0<\/span><\/p>\n

This system therefore relies, above all, on the strong commitment of the employees concerned to devising the ideas, means and tools for continuous improvement in all sectors of the company (finance, production, administration, product development, etc.).<\/span>\u00a0<\/span><\/p>\n

The\u00a0method\u00a0is\u00a0divided\u00a0into\u00a0several\u00a0steps.\u00a0We\u00a0first\u00a0identify\u00a0the\u00a0problem:\u00a0what\u00a0difficulty\u00a0do I have in\u00a0my\u00a0current\u00a0process. To\u00a0respond\u00a0to\u00a0this,\u00a0you\u00a0can, for\u00a0example,\u00a0work\u00a0on\u00a0order\u00a0processing\u00a0times. There\u00a0is\u00a0a process\u00a0known\u00a0as \u201cKaizen Blitz\u201d, a version of the\u00a0method\u00a0condensed\u00a0into\u00a0three\u00a0days. It\u00a0is\u00a0applied\u00a0for simple\u00a0processes,\u00a0which\u00a0involve\u00a0two\u00a0or\u00a0three\u00a0departments.<\/span>\u00a0<\/span><\/p>\n

The main\u00a0feature\u00a0of Kaizen Blitz\u00a0is\u00a0fun. Games,\u00a0videos,\u00a0<\/span>Post-it notes<\/span>,\u00a0arrows, a large\u00a0airy\u00a0room\u00a0with\u00a0<\/span>flip charts<\/span><\/a>,\u00a0colour<\/a><\/span>ful<\/span>\u00a0markers,\u00a0space\u00a0to move\u00a0around\u00a0the room\u00a0freely, etc. The major\u00a0advantage\u00a0of Kaizen Blitz\u00a0is\u00a0that, the\u00a0very\u00a0next\u00a0morning, the new process can\u00a0be\u00a0put in place and\u00a0its\u00a0impact\u00a0analysed. Of course,\u00a0this\u00a0method\u00a0is\u00a0not\u00a0just\u00a0a\u00a0three-day\u00a0project, but\u00a0it\u00a0brings\u00a0about\u00a0improvements\u00a0in\u00a0everyday\u00a0life. The team\u00a0takes\u00a0the initiative to\u00a0ask\u00a0questions in the\u00a0context\u00a0of\u00a0this\u00a0new\u00a0approach.<\/span>\u00a0<\/span><\/p>\n

Kaizen method continuous improvement tools<\/span><\/h2>\n

The Kaizen\u00a0method\u00a0makes\u00a0use of\u00a0several\u00a0management\u00a0tools\u00a0to\u00a0improve\u00a0quality\u00a0of life at\u00a0work:<\/span>\u00a0<\/span><\/p>\n

    \n
  • The 5S\u00a0method,\u00a0which\u00a0makes\u00a0better\u00a0use of time and optimises\u00a0working\u00a0conditions;<\/span>\u00a0<\/span><\/li>\n
  • SMED (Single Minute Exchange of Die),\u00a0which\u00a0consists\u00a0of\u00a0optimising\u00a0transitions in production and\u00a0eliminating\u00a0downtime;<\/span>\u00a0<\/span><\/li>\n
  • TQM (Total\u00a0Quality\u00a0Management),\u00a0which\u00a0focuses\u00a0on production conditions and the\u00a0quality\u00a0of the\u00a0product\u00a0or\u00a0service;<\/span>\u00a0<\/span><\/li>\n
  • Lean Management,\u00a0which\u00a0aims\u00a0to\u00a0improve\u00a0inventory\u00a0management and\u00a0reduce\u00a0losses\u00a0and\u00a0waste\u00a0as\u00a0much\u00a0as\u00a0possible;<\/span>\u00a0<\/span><\/li>\n
  • The Deming Wheel,\u00a0whose\u00a04-step process (Plan, Carry out,\u00a0Predict\u00a0and\u00a0Act) leads to\u00a0continuous\u00a0improvement\u00a0in\u00a0productivity\u00a0at\u00a0work.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

    What are the main principles to follow to set up the Kaizen method?<\/span><\/h2>\n

    To\u00a0be\u00a0effective, the Kaizen system\u00a0requires\u00a0a\u00a0number\u00a0of\u00a0principles\u00a0and conditions to\u00a0be\u00a0met:<\/span>\u00a0<\/span><\/p>\n

      \n
    • Constant\u00a0reappraisal,\u00a0even\u00a0when\u00a0things\u00a0are\u00a0going\u00a0well, in\u00a0order\u00a0to\u00a0remain\u00a0competitive\u00a0in the long\u00a0term;<\/span>\u00a0<\/span><\/li>\n
    • Not\u00a0aiming\u00a0for perfection and setting\u00a0realistic\u00a0and\u00a0gradual\u00a0goals for\u00a0change;<\/span>\u00a0<\/span><\/li>\n
    • Identifying\u00a0the\u00a0problem(s)\u00a0causing\u00a0the\u00a0dysfunction\u00a0in\u00a0order\u00a0to\u00a0resolve\u00a0it;<\/span>\u00a0<\/span><\/li>\n
    • Resolving\u00a0problems\u00a0as\u00a0soon\u00a0as possible\u00a0so\u00a0as not to let the situation\u00a0escalate;<\/span>\u00a0<\/span><\/li>\n
    • Prioritising\u00a0the changes to\u00a0be\u00a0made, for instance, by\u00a0creating\u00a0lists,\u00a0is\u00a0advisable\u00a0to\u00a0ensure\u00a0that\u00a0the system\u00a0is\u00a0implemented\u00a0in the best possible\u00a0way;<\/span>\u00a0<\/span><\/li>\n
    • Being\u00a0aware\u00a0of the time\u00a0needed\u00a0to\u00a0implement\u00a0the new\u00a0working\u00a0policy\u00a0and putting\u00a0into\u00a0perspective the\u00a0mistakes\u00a0that\u00a0can\u00a0be\u00a0made;<\/span>\u00a0<\/span><\/li>\n
    • Involving\u00a0all team\u00a0members\u00a0to\u00a0achieve\u00a0coordinated\u00a0results\u00a0over time and\u00a0continuous\u00a0improvement\u00a0in\u00a0productivity.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

      How to put the Kaizen method in place<\/span><\/h2>\n

      Following the\u00a0theoretical\u00a0definition, let us\u00a0now\u00a0consider\u00a0the\u00a0practical\u00a0implementation\u00a0of the\u00a0tools\u00a0of\u00a0this\u00a0method\u00a0of management in\u00a0companies\u00a0and the optimisation of\u00a0working\u00a0conditions.<\/span>\u00a0<\/span><\/p>\n

      Analyse the causes and find solutions together<\/span>\u00a0<\/span><\/h3>\n

      The\u00a0priority\u00a0is\u00a0to\u00a0map\u00a0each\u00a0process,\u00a0step\u00a0by\u00a0step,\u00a0with\u00a0all\u00a0their\u00a0details\u00a0and\u00a0timescales. Teams are\u00a0often\u00a0surprised\u00a0at the\u00a0complexity\u00a0of the\u00a0processes\u00a0they\u00a0use on a\u00a0daily\u00a0basis and the\u00a0inherent\u00a0waste\u00a0of time.<\/span>\u00a0<\/span><\/p>\n

      Next,\u00a0it\u00a0is\u00a0necessary\u00a0to\u00a0identify\u00a0the causes of the\u00a0dysfunctions\u00a0observed. There\u00a0is\u00a0a\u00a0method\u00a0known\u00a0as \u201cThe 5\u00a0Whys\u201d,\u00a0which\u00a0helps\u00a0you\u00a0find\u00a0the root causes of\u00a0problems.<\/span>\u00a0<\/span><\/p>\n

      Apply the main steps of the process<\/span><\/h3>\n

      The\u00a0implementation\u00a0of the Kaizen\u00a0method\u00a0is\u00a0based\u00a0on 6\u00a0main\u00a0steps:<\/span>\u00a0<\/span><\/p>\n

        \n
      1. Define\u00a0the\u00a0problem;<\/span>\u00a0<\/span><\/li>\n
      2. Measure\u00a0its\u00a0scale\u00a0(mapping of the process,\u00a0supplemented\u00a0by\u00a0statistics,\u00a0timescales);<\/span>\u00a0<\/span><\/li>\n
      3. Analyse the causes of the\u00a0dysfunctions;<\/span>\u00a0<\/span><\/li>\n
      4. Define\u00a0breakthrough\u00a0solutions as\u00a0well\u00a0as changes\u00a0that\u00a0can\u00a0be\u00a0made to the\u00a0system;<\/span>\u00a0<\/span><\/li>\n
      5. Evaluate\u00a0the relevance of the\u00a0measures\u00a0taken\u00a0and the\u00a0tools\u00a0used, and\u00a0define, if\u00a0necessary, areas for\u00a0improvement\u00a0for\u00a0this\u00a0new\u00a0system;<\/span>\u00a0<\/span><\/li>\n
      6. Implement\u00a0and\u00a0sustain\u00a0the process in the long\u00a0term.<\/span>\u00a0<\/span><\/li>\n<\/ol>\n

        Secure and sustain this strategy for continuous improvement<\/span>\u00a0<\/span><\/h3>\n

        In\u00a0its\u00a0implementation, the Kaizen\u00a0method\u00a0relies in\u00a0particular\u00a0on\u00a0visual\u00a0management:\u00a0once\u00a0defined, the\u00a0tasks\u00a0to\u00a0be\u00a0accomplished\u00a0are \u201cmaterialised\u201d in the\u00a0form\u00a0of\u00a0lists, tables or\u00a0diagrams\u00a0which\u00a0are\u00a0then\u00a0displayed\u00a0on a\u00a0wall\u00a0or a flip chart to\u00a0make\u00a0them\u00a0easier\u00a0to\u00a0understand\u00a0and\u00a0remember. This\u00a0visual\u00a0aspect\u00a0also\u00a0helps\u00a0to\u00a0instil\u00a0the system\u00a0among\u00a0staff and to monitor performance.<\/span>\u00a0<\/span><\/p>\n

        The concrete results of the Kaizen method<\/span><\/h3>\n

        The\u00a0successful\u00a0application of the Kaizen\u00a0method\u00a0leads, in the medium\u00a0term, to positive changes and\u00a0results\u00a0at\u00a0several\u00a0levels\u00a0of the\u00a0company:<\/span>\u00a0<\/span><\/p>\n

          \n
        • It\u00a0significantly\u00a0optimises the\u00a0working\u00a0conditions of\u00a0employees\u00a0and\u00a0contributes\u00a0to\u00a0greater\u00a0staff\u00a0engagement;<\/span>\u00a0<\/span><\/li>\n
        • It enables\u00a0continuous\u00a0improvement\u00a0of\u00a0productivity\u00a0and optimisation of time and production\u00a0schedules;<\/span>\u00a0<\/span><\/li>\n
        • The system\u00a0ultimately\u00a0guarantees\u00a0that\u00a0the\u00a0products\u00a0or services\u00a0sold\u00a0are of\u00a0better\u00a0quality.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"

          Lean Six Sigma is a method of continuous improvement that involves all actors in a process to eliminate waste, i.e. anything that reduces the efficiency and performance of a production unit or the entire company. \u00a0...<\/p>\n","protected":false},"author":9,"featured_media":22847,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":[],"categories":[76],"tags":[116,18],"yoast_head":"\nKaizen method: how to continuously improve your company\u2019s performance - Manutan UK Blog<\/title>\n<meta name=\"description\" content=\"Principles, techniques, advantages, implementation... 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