Kaizen

Lean Yellow Belt Tool Kaizen

What is Kaizen

Kaizen (Continuous Improvement) is a method where employees work together proactively to achieve regular, incremental improvements of processes.

Properties:

  • A Kaizen is a small improvement project.
  • Using incremental small improvements instead of major changes. All small improvements added up make for big improvements as well.
  • Bottom-up approach; the employees working in a process know best where improvements can be found.
  • Relatively short duration (days/weeks instead of months/years).

Why Kaizen

General advantages

  • Improves processes, outputs and morale.

Reduces waste types

When to use Kaizen

Essential conditions

Gemba

To get information and input from the work floor.

Standardized Work

To sustain improvement results.

Non-essential conditions

Change management

To facilitate a smooth improvement process.

Motivation

To enhance improvement results.

PDCA

Provides the roadmap for the improvement efforts.

Root Cause Analysis

To identify the root cause of problems.

SIC

To help identify improvement opportunities.

How to implement and use Kaizen

Implementation

General comments:

  • Empower employees to do Kaizens.
  • Be receptive to new ideas and suggestions.
  • Create commitment for teamwork.

Use

Suitable situations:

  • Responsibility for the implementation of improvement lies mostly within the team.
  • Small risk of failure.
  • Clearly defined.
  • Improvement opportunities visible (e.g. waste).
  • Time-restricted, effects are quickly expected.

Guidelines:

  • (Internal) customer is always the starting point.
  • Conducted at Gemba.
  • Speed over thoroughness (better 80% right fast, than 100% right too late).
  • Use process roadmap (e.g. PDCA or DMAIC).

Where to find it

IASSC Body of Knowledge:

Lean: 3

Yellow ➔ Apply
Green ➔ Analyze
Black ➔ Create

Lean Six Sigma: 5.1

Yellow ➔ Apply
Green ➔ Apply
Black ➔ Apply

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About the Author

Floris Lap is an IASSC-certified Lean Six Sigma Black Belt and founder of Procestimal. He empowers organizations to maximize value and reduce waste through practical Lean Six Sigma solutions—contributing to a more sustainable world where businesses thrive with minimal resources. Contact us

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