Gemba Kaizen

Kaizen Definition

KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination

What is MUDA?

Muda means any wasteful activity or any obstruction to smooth flow of an activity

Activity = Work + Muda

Expenditure = Cost + waste

That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!

Therefore, Less Muda = More happy clients (as it impacts on quality, cost and delivery of products and services).

What is Gemba?

Gemba - Real place - (in our context Work Place)

Gembutsu - tangible objects found at the Gemba

Gemba is where Value Is Added. (The Managers cabin is not a Gemba !)

What is Gemba Kaizen®?

A process of Continuously

• Identifying
• Reducing
• Eliminating

Muda from our Gemba

Some typical misconceptions on Kaizen

• Kaizen is for workers; It is not for managers
• Kaizen is SMALL improvements only
• Kaizen is only a sort of implemented-suggestion scheme
• Any implemented improvement is Kaizen
  

When does it become KAIZEN?

• large improvements are made
• small time and small money is used
• bottleneck problem is attacked
• process observation is used
• KAIZEN paradigms are deployed
• management participation exists

Gemba Kaizen® also Focuses on Mura and Muri

What is Mura?

Mura = Inconsistencies in the system

• Happens sometimes?
• Happens some places
• Happens to some people
• One side is ok; the other side is not ok

All this is Mura

What is Muri?

Muri = Physical Strain

• Bend to work?
• Push hard?
• Lift weight?
• Repeat tiring action?
• Wasteful walk?

All this is Muri

Gemba kaizen®, now redefined …..

A process of Continuously

• Identifying
• Reducing
• Eliminating

Muda, Mura , Muri (3 Mu) from our Gemba

Carrying out GEMBA KAIZEN® Workshops involve:

• Focused Improvement
• Setting up of Cross-functional teams
• A KAIZEN Time slot (4 to 5 days)
• Applying 5 golden rules of Gemba management
• Avoid spending money (no investment)
• Working in PDCA cycle
  

Five Golden Rules Of Gemba Kaizen® Workshop

1) Go to the Gemba

2) Check Gembutsu - (item at Gemba)

3) Take Temporary Measures on the spot

4) Find root cause & kill

5) Standardize to Prevent Recurrence

PDCA Cycle

Improve what you maintain
Maintain what you improve

How to Observe?

• Go to the gemba
• Do cleaning yourself
• Do not sit anywhere
• Do not ask for ideas
• Look first for Muda
• Then look for Mura
• Finally look for Muri

5-S

5S is the foundation of Kaizen. All Gemba Kaizen workshop should start by applying the concept of 5S.

Some key benefits of Kaizen

• Process Improvement
• Observation
• Use of new Paradigms
• Short time
• Zero Investment
• Human Development
• Profits & Savings

Kaizen: learn by doing.

More details on Gemba Kaizen®>>