KAIZEN

GEMBA

CONTENTS

• BASIC CONCEPT

• KAIZEN TOOLS

• GEMBA

• 5 GEMBA PRINCIPLES

• LOW COST APPROACH

• GROUND RULES

• BENEFITS OF KAIZEN GEMBA

Kaizen Gemba

Kaizen means continuous improvement.

Gemba is a Japanese word meaning 'real place,‘

where the real action takes place.

The concept of Kaizen was given by Masaki Imai who

was more a practitioner rather than a philosopher.

Who does KAIZEN ? Why ?

http://www.kaizen.com/5

KAIZEN TOOLS

• Quality Circle

• PDCA

• 5 S

• Kanban-Lean Manufacturing-Just In Time

• Poka Yoke-Mistake Proofing-Zero Quality Control by humans.

• So,we all are well aware about various Kaizen

Tools which when applied will help to achieve

quality.

• But friends…..the question is – Where to apply

these tools??????

KAIZEN GEMBA

• The answer is- Gemba.

• Where can the value addition be done??

1. While developing a product.

2. While producing/manufacturing.

3. While selling.

• Management gives more importance to 1 & 3.

• Customer Point of View-2 is more important.

• For balance-Gemba required.

5 GEMBA

PRINCIPLES

1

2

Gembutsu

3

Countermeasures

4

ROOT CAUSE

5

Gemba KAIZEN - Low cost approach

In order to solve problems found in

gemba, today’s managers often try to apply

sophisticated tools and technologies to deal with

problems that can be solved with a

commonsense, low-cost approach.

2 APPROACHES

Ground rules for practicing

Kaizen in gemba:

1. Housekeeping,

2. Muda elimination.

3. Standardization.

Housekeeping is an indispensable ingredient

of good management. Through good

housekeeping, employees acquire and practice

self-discipline. Employees without self-

disciplines make it difficult to provide

products or services of good quality to the

customer.

1. Housekeeping

23

5S is a method for organizing

a workplace, especially a shared

workplace (like a shop floor or

an office space), and keeping it

organized.

2. Muda elimination

In Japanese, the word muda means waste.

Any activity that does not add value is

muda.

People in gemba either add value or do not add

value. This is also true for other

resources, such as machines and materials.

Muda elimination can be the most cost-

effective way of improving productivity and

reducing operating costs.

3. Standardization

• Standards may be defined as the best way to do the job

• Products or services are created as a result of a series of

processes. Certain standard must be maintained at each process

in order to assure quality.

• Standards also can prevent recurrence of the same problem

25

Benefits of kaizen

Kaizen Reduces Waste like

inventory waste, time

waste, workers motion

Kaizen Improves space

utilization, product quality

Results in higher employee moral

and job satisfaction, and lower turn-

over.

Toyota is well-known as one of the

leaders in using Kaizen. In 1999 at

one U.S. plant, 7,000 Toyota

employees submitted over 75,000

suggestions, of which 99% were

implemented. 26