Kaizen
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ЁЯУЪ
LearningTranscript
00:00The word kaizen in Japanese can actually be broken down into two separate words, where
00:27k equals change and zen equals good, simply meaning change for better. In English, kaizen
00:37is typically applied for implementing continuous improvement.
00:43Kaizen is an approach to activity organisation based on common sense, self-discipline, order
00:49and economy. The kaizen method is a strong contributor and fundamental part of a lean
00:56production process model in lean manufacturing. It also applies to lean software development.
01:07The history of kaizen begins after World War 2, when Toyota first implemented quality cycles
01:13in its production processes. This was influenced in part by American business and quality management
01:18teachers who visited the country. Masakai Imai is a Japanese organisational theorist
01:25and management consultant, known for his work on quality management, specifically on
01:31kaizen. In 1985, he founded the Kaizen Institute Consulting Group.
01:39The kaizen methods follow ten specific principles, which are described below.
01:441. Improve everything continuously. 2. Abolish old, traditional concepts.
01:513. Accept no excuses and make things happen. 4. Say no to the status quo of implementing
01:59new methods and assuming they will work. 5. If something is wrong, correct it.
02:106. Empower everyone to take part in problem solving.
02:157. Get information and opinions from multiple people.
02:198. Before making decisions, ask why five times to get to the root cause.
02:269. Be economical. Save money through small improvements,
02:30and spend the money saved on further improvements.
02:3310. Remember that improvement has no limits. Never stop trying to improve.
02:42Here we see the questions that should be asked, as in Principle 8.
02:47The five W's and one H of kaizen. The who, what, where, when, and why, as well as the how.
02:56The kaizen method strives towards perfection by eliminating waste, muda, in the workplace.
03:03The goal of kaizen is production without wastes by improving standardized activities and processes.
03:10Industrialization is a process of eliminating waste, muda, in the workplace.
03:15The goal of kaizen is production without wastes by improving standardized activities and processes.
03:21Industrial engineer, Taichi Ono, the father of the Toyota production system,
03:26noticed that there was an 80% loss in every process, and the value of the process is less than 20%.
03:37After analyzing manufacturing processes,
03:39Taichi Ono was able to identify which steps add value and which ones do not.
03:45As a result, he developed a better way for organizations to identify
03:49waste with his 7-waste model. These wastes include...
03:541. Delay. Waiting or time spent in a queue with no value being added.
04:00A large part of an individual product's life is spent waiting to be worked on.
04:052. Producing more than you need. Overproduction usually hides and or generates all the others.
04:13It leads to excessive inventory, which then requires the expenditure of time and effort.
04:193. Overprocessing or undertaking non-value-added activity.
04:31Overprocessing occurs when more work is performed on a piece than what's required by the customer.
04:414. Transportation. Each time a product is moved,
04:45it stands the risk of being damaged, lost, delayed, etc., as well as being a cost for no added value.
04:525. Unnecessary movement or motion. Motion refers to the damage that the
04:57production process inflicts on the entity that creates the product. This may be over time,
05:03wear and tear for equipment, and repetitive strain injuries for the workers, or,
05:07during discrete events, accidents that damage equipment and or injure workers.
05:136. Inventory. Whether it's in the form of raw materials, work in progress, or finished goods,
05:20represent a capital outlay that has not yet produced an income, either by the producer
05:26or for the consumer. 7. Production of defects.
05:31Defects cause extra cost for reworking the part,
05:35and can sometimes result in doubling the cost of one single product.
05:42you