1. IAQ Symposium – 2nd IAQ World Quality Forum Kaizen System Implementation
Balázs Németh, PhD.
2017.

2. KAI ZEN Continuous improvement
Change + Better
Continuous improvement
Small frequent improvements by the involvement of everyone.
Low cost (no investment)
Change of method
Perfection of the existing (standards) ways of working
Long term process

3. Kaizen Philosophy Customer Focus Continuous Improvement (PDCA)
Follow standards and continuously improve standards
Total Participation (involvement)
Process Thinking (Next process is your customer)
Management by Facts (Data)
Small step improvements

4. SDCA and PDCA cycle D C P A A S C D Improvement (KAIZEN) Maintenance
(Daily work)

5. KAIZEN Change of method Different method Different result
equipment

6. Levels of Kaizen Application
Individual Kaizen ideas
Small group acitvities problem solving - QCC
Management
Level
Kaizen

7. Elements of Kaizen activity
Set Kaizen goals
Recognize Kaizen opportunities
Generate ideas for improvement
Decision about and implementation of improvement
Evaluate, recognize and share Kaizen ideas
Management
Employees
Management

8. Kaizen process Feedback New Method, Solution Identify Improvement
Opportunity
Collect Data,
Understand Situation
Generate Solutions
(Kaizen ideas)
Evaluate Kaizen ideas
Feedback
Implement Selected
Solution
New Method,
Solution
Follow Up and
Evaluation

9. Tube (handrail) bending No cleaning time, no source of dirt
Date:
Operation
Problem
Actions
Results
Bending is done without oil, quality is OK…
Tube (handrail) bending
Removing oil from the handrail takes long time (2 min), dirty..
No cleaning time, no source of dirt
Before Kaizen
After Kaizen
Bending without oil 9
BEST PRACTICE 9

10. Management is creating the right conditions for Kaizen
Create & Maintain
Management
Conditions
Create & Maintain
Supervisors
Processes
Documenting
Standardization
Evaluation
of ideas
Create
Employees
Results
Sharing
solutions
Shopfloor
Mgmt.
Kaizen activities
Lean Thinking
Problem
Solving
Collection
of ideas
Shared
Values
Vision
Kaizen
Coordinators
Performance
measurement &feedback
Evaluation of
Performance
Clear Expectations
Kaizen Training
Resource allocation

11. Elements of effective Kaizen mechanism
Problem centric
„good sheperd” approach
Lean, Kaizen knowledge,
methods, coordination
Empowerment
decisions, resources
Accountability,
Recognition
Identify the
problem
Problem
analysis
Finding
solution
Implementation
PDCA
Evaluating
the results
Goals, expectations, Standards
Standards,processes, practice
Data collection
Problem catalogue
Failure cards
Brain storming
Value Stream Mapping
Kaizen workshop, 7 QC tools
5 Why? 7 MUDA, 3MU, 4M..
Structured problem solving
Kaizen Log
Monitoring
Card board engineering
Lean KPIs
Lean Audit
Layered Audit

12. Preconditions of Successful Kaizen
Top Management Commitment
Team leaders and supervisors Commitment
Provide time and Resources
Training, Kaizen knowledge
Clear Strategy, Goals and Expectations
Quick Feedback (about performance, and also for suggestions)
Kaizen Process
Coordination
Stability in the current operations, Standard Work
Feedback about the current performance.
Problem awareness of people
Empowerment of People
Kaizen

13. Kaizen Culture Non Blaming Culture. Problem is an opportunity
Openness and Learning culture.
Cooperation and team work.
Customer orientation, Customer focus.
Discipline
Management by Facts. 3 GEN (Gemba, Gembutsu, Genjitsu).

14. Integrating Kaizen into daily work
Plan kaizen activities into daily work and give time to do it
Make the Kaizen become part of everyday work
Provide the necessary Human and Financial resources for the implementation of Kaizen
Continually train the workers and Monitor Kaizen results

15. Kaizen Event - Agenda

16. Brush Transformation

17. Layout Transformation

18. Kaizen Event
Before Kaizen
After Kaizen

19. Kaizen workshop Before KAIZEN After KAIZEN
Result: 50% area reduction, one piece flow, 60% inventory reduction, FIFO

20. Preconditions of successful Kaizen activity
Top management support
Kaizen thinking, culture
Chance to change things
Available resources
Interested and motivated people
Feedback 20

21. Further Information Kvalikon Consulting Ltd.
Budapest, HU-1125 Istenhegyi út 63/B
Telephone: (+36-1) ,
Web: