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7 Steps of Kobetsu Kaizen Process

Kaizen is a Japanese philosophy of continuous improvement. The document outlines a 7 step process for carrying out Kaizen activities: 1) select an improvement topic and form project teams, 2) understand the current situation by identifying bottlenecks and measuring losses, 3) expose and eliminate abnormalities by studying processes and restoring equipment, 4) analyze causes using various techniques, 5) plan improvements by proposing solutions and checking for disadvantages, 6) implement improvements through testing and providing instructions, and 7) check results, consolidate gains by preparing standards, and train others to sustain results.

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Rakesh Tigadi
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143 views3 pages

7 Steps of Kobetsu Kaizen Process

Kaizen is a Japanese philosophy of continuous improvement. The document outlines a 7 step process for carrying out Kaizen activities: 1) select an improvement topic and form project teams, 2) understand the current situation by identifying bottlenecks and measuring losses, 3) expose and eliminate abnormalities by studying processes and restoring equipment, 4) analyze causes using various techniques, 5) plan improvements by proposing solutions and checking for disadvantages, 6) implement improvements through testing and providing instructions, and 7) check results, consolidate gains by preparing standards, and train others to sustain results.

Uploaded by

Rakesh Tigadi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

“Kaizen” = Fill difference between

present status and goal

• KAI-----------CHANGE

• ZEN----------BETTER

CONTINUOUS IMPROVEMENTS
7 steps for carrying out the Kobetsu Kaizen activities
Step Details Activity
Step 0 Select improvement 1. Select and register topic
topic 2. Form project teams
3. Plan activities
Step 1 Understand situation 1. Identify bottleneck process
2. Measure failures, defects and other losses
3. Use baselines (Bench Mark) to set targets
Step 2 Expose and eliminate 1. Thoroughly study and expose abnormalities
abnormalities 2. Restore deterioration and correct minor flaws
3. Establish basic equipment condition
Step 3 Analyze causes 1. Stratify and analyze causes
2. Apply analytical techniques (why-why analysis,
Why OK analysis etc.)
3. Conduct experiments, apply specific
technology, fabricate prototypes
Step Details Activity
Step 4 Plan improvements 1. Make improvement proposals and prepare
drawings
2. Compare cost effectiveness of alternate
proposals and make budget
3. Check for possible adverse effects and
disadvantages
Step 5 Implement 1. Carryout improvement plan
improvements 2. Perform tests, trial runs
3. Provide instructions to work on improved
equipment, operating conditions.
Step 6 Check results 1. Evaluate results with time as improvement
project goes on
2. Check whether targets have been achieved, if
not start from step 3 again
Step 7 Consolidate gains 1. Prepare inspection and work standards
2. Make drawings and feed information to
Development management Pillar
3. Train operators and or fitters to sustain the
results

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