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Masaaki Imai made the term famous in his book Kaizen: The Key to Japan's Competitive Success. [1] In the Toyota Way Fieldbook, Liker and Meier discuss the kaizen blitz and kaizen burst (or kaizen event) approaches to continuous improvement. A kaizen blitz, or rapid improvement, is a focused activity on a particular process or activity.
Kaizen is based on the involvement of all employees, wherein singular changes typically do not improve major production metrics above a 20% threshold. A cross between Kaikaku and Kaizen is Kaizen Blitz (or Kaizen Events), which targets a radical improvement in a limited area, such as a production cell, typically during an intense week.
Example of a worksheet for structured problem solving and continuous improvement. A3 problem solving is a structured problem-solving and continuous-improvement approach, first employed at Toyota and typically used by lean manufacturing practitioners. [1]
Genba (現場, also romanized as gemba) is a term used in business for the location where value is created, such as a factory floor, construction site, or sales floor. [1]In lean manufacturing, the most valuable ideas for improvement are thought to occur at the genba where problems are visible.
Data capture template. Parallel operations using multiple operators By taking the 'actual' operations and making them into a network which contains the dependencies it is possible to optimize task attribution and further optimize setup time. Issues of effective communication between the operators must be managed to ensure safety is assured ...
The plan–do–check–act cycle. PDCA or plan–do–check–act (sometimes called plan–do–check–adjust) is an iterative design and management method used in business for the control and continual improvement of processes and products. [1]