Case study on kaizen concept
Samsung took an approach to its business where it wanted to combine Japanese production processes with US cultures of working. Jaeyong Song from an interview in Industry Week :. The outcomes of the New Management initiative were astounding. Generally, Japanese management is characterized by market share orientation, unrelated diversification, vertical integration, emphasis on manufacturing competitiveness and operational efficiency, strict organizational discipline, emphasis on employee loyalty, internal and seniority-based promotion and rewards, and participation of both workers and shareholders in management.
The American management style, on the other hand, emphasizes profits and revenue, focusing on relevant industries and frequently restructuring businesses and products. American companies also tend to outsource manufacturing or move abroad, finding the source of their core competencies in soft capabilities or intangible assets such as technological innovation, brand marketing capabilities, and design capabilities.
Now, you might be wondering where kaizen comes into this. Samsung have plants in South Korea. The workers at these plants are highly trained and are skilled employees. However, Samsung — taking American influence — also have factories which are quasi-outsourced. In these factories, the tasks are simpler and the workers less specialized. In these environments there is less of an effort to employ kaizen techniques like the one demonstrated in our case study in this article.
Instead, those factories use different methodologies. The flexibility here demonstrates that kaizen is best when used in the right environments. Have you been a strict adherent of kaizen approaches in your business? What were your experiences?
Let us know in the comments below! Adam Henshall is a content writer for Process Street and dabbles in other projects inc Idyoma on the side. Living in Sevilla in the south of Spain, Adam's current hobby is learning Spanish! Article gives deeper insight into tested processes through the comparative approach.
We're hiring. Business Processes , Management , Manufacturing. So how do we approach this improvement to get the most from it?
The key is about making improvement part of the daily process. Things to consider when implementing Kaizen. How Samsung use Kaizen selectively to optimize production Why Kaizen is important Source Kaizen is a big deal because broadly speaking it works. Kaizen is one of the real key elements of this approach so deserves our time. We even use it at Process Street! As explained in an article in the Harvard Business Review : In contrast, people in sales and marketing, which emphasize relationships and innovation, are less likely to embrace it readily.
What is Kaizen? Expanding on that initial paragraph with: Kaizen means all personnel are expected to stop their work when they encounter any abnormality and, along with their supervisor, suggest an improvement to resolve the abnormality. The key takeaway from this definition is the idea of incremental improvements. Once the main flow of a process is established, improving the small details can have a cumulative effect. So really we have three key theoretical things laid out there for us: The epistemology of a process.
Processes evolve and are discovered as much as designed.
Operations must be practical and achieve business goals. Small details are often causes of defects and problems. Removing them creates compounded benefits. Assemble workers around a problem The company firstly assembled a team of skilled stakeholders to undertake the process improvement investigation: In order to address this system design problem, a design engineer, a manufacturing engineer, a quality engineer, and two machining operators were invited to be team members in this Kaizen project. Understand the existing process and map alternatives This process mapping was done with measurements of how long each part takes to create, how far each part needs to travel, and how assembly is managed.
These 7 alternative process ideas were then mapped and displayed together on a visual chart. The metrics given were as follows: The decision was made to evaluate this project based on the following criteria: a flexibility: with two subcriteria: simplicity and ease of repetition; b cost: with five subcriteria: capital investment, labor costs, tooling costs, known technology, and required maintenance costs; and c safety: with seven subcriteria: safe, clean, ergonomic, of desired quality, required skills, defects per shift, and meets customer specifications.
After intense discussion and research, the final decisions need to be made. Test your improved process and measure the results Once the new process had been chosen for testing, the team sets to work drawing up detailed instructions for each worker who will be involved in the process.
The theory was then to be put to the test. The results of this test: The existing cycle time per assembly was 62 seconds. Kaizen speeds up decision making Source One of the key takeaways worth expanding on lies in the conclusion of the report. Form a team. Gather information from internal and external customers, and determine goals for the project.
Review the current situation or process. Brainstorm and consider seven possible alternatives.
Decide the three best alternatives of the seven. Simulate and evaluate these alternatives before implementation. Present the idea and suggestions to managers. Physically implement the Kaizen results and take account of the effects.
Role of Kaizens to Improve Productivity: A Case Study
What are the other Toyota Production System concepts? Muda: How to identify waste Muda is the Japanese word for waste and the Toyota system has a key emphasis on the removal of waste at each turn. Sughanthi Anand A Samuel. Prajogo a, Amrik S. Sohal b. Gunasekaran and P. Kaizen is more than continuous improvement, Quality Progress 27, All Rights Reserved.
Kaizen (continuous improvement)
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Article Preview. Abstract: Continuous improvement is a vital component of an effective performance management system. Add to Cart. Applied Mechanics and Materials Volumes Main Theme:. Dynamics of Machines and Mechanisms, Industrial Research. Edited by:. Balasubramanian, S. It was passed in the traditional platform that consisted of five important concepts namely teamwork, improved morale, quality, personal discipline, as well as suggestions for improvement. The five aspects of Kaizen largely contributed to three main results namely the elimination of wastes, standardization of ethical practices at work, and good housekeeping.
The Kaizen concept goes ahead to poise that there is no perfect end to these activities of improvement. However, a lot can be achieved with best practices.
Improve Your Business Through Kaizen
At the core of Kaizen is teamwork, thereby making the philosophy a team-building strategy. Cooperation is the main buzzword for all organizations. However, very few companies implement it. The disconnect existing in the corridors of the organizations calls for the implementation of the Kaizen policy.