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How can you make kaizen activities sustainable and not just one-time events?

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Kaizen is a Japanese word that means continuous improvement. It is a core principle of lean manufacturing, which aims to eliminate waste, increase efficiency, and deliver value to customers. Kaizen activities are small, incremental changes that involve everyone in the organization, from the shop floor to the top management. They can be implemented through various methods, such as kaizen events, suggestion systems, gemba walks, or daily huddles. However, kaizen is not a one-time event, but a continuous process that requires commitment, discipline, and follow-up. How can you make kaizen activities sustainable and not just one-time events? Here are some tips to help you.

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Asanka Henegedara

Facilitated 10,000+ Gemba Kaizens in 50+ Organizations | Director - Center for Lean Excellence | Certified TPS…

1 Set clear and realistic goals

Before you start any kaizen activity, you need to have a clear and realistic goal that aligns with your strategic objectives and customer needs. A goal should be specific, measurable, achievable, relevant, and time-bound (SMART). For example, you can set a goal to reduce the cycle time of a certain process by 10% in one month. Having a clear and realistic goal will help you focus your efforts, monitor your progress, and celebrate your achievements.

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Asanka Henegedara

Facilitated 10,000+ Gemba Kaizens in 50+ Organizations | Director - Center for Lean Excellence | Certified TPS Practitioner
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Clear targets are very crucial. Toyota gives a target of minimum two Kaizens per month for its all employees. In the initial stages you can give a target of one kaizen per week as there can be many opportunities in the beginning.

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2 Involve and empower your team

Kaizen is not a top-down approach, but a bottom-up one. It relies on the involvement and empowerment of your team members, who are closest to the problems and the solutions. You need to create a culture of trust, respect, and collaboration, where everyone can share their ideas, feedback, and suggestions without fear of criticism or punishment. You also need to provide your team with the necessary training, tools, and resources to implement their kaizen activities. By involving and empowering your team, you will increase their motivation, engagement, and ownership of the results.

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Asanka Henegedara

Facilitated 10,000+ Gemba Kaizens in 50+ Organizations | Director - Center for Lean Excellence | Certified TPS Practitioner
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You need to train your team on the fundamentals of kaizen. They need to know the basics of Value Adding and Non Value Adding or Muda. Train them how to see Muda in their work environment. Ask them to do their first kaizen. Evaluate it and appreciate the effort. Kaizen is not only about making improvements, it also encompasses self satisfaction with a sense of accomplishment. Let them feel it, make them realize that doing kaizen is actually gives more meaning to their work and lives.

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3 Track and measure your results

Kaizen is not about making random changes, but about making data-driven decisions. You need to track and measure your results to see if your kaizen activities are effective and efficient. You can use various tools and metrics, such as key performance indicators (KPIs), control charts, run charts, or pareto charts, to monitor your performance and identify any gaps or opportunities for improvement. You also need to document and communicate your results to your team, your management, and your customers, to show the impact and value of your kaizen activities.

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4 Review and standardize your processes

Kaizen is not about making temporary fixes, but about making permanent improvements. You need to review and standardize your processes to ensure that your kaizen activities are consistent and sustainable. You can use tools such as checklists, flowcharts, work instructions, or visual aids, to document and communicate your best practices and procedures. You also need to audit and verify your processes regularly to check if they are followed and maintained. By reviewing and standardizing your processes, you will prevent backsliding and reinforce the new behaviors and habits.

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5 Seek and embrace feedback

Kaizen is not about being complacent, but about being curious and humble. You need to seek and embrace feedback from your team, your management, your customers, and your suppliers, to learn from their perspectives and experiences. You can use tools such as surveys, interviews, focus groups, or customer reviews, to collect and analyze feedback. You also need to act on the feedback and make any necessary adjustments or corrections. By seeking and embracing feedback, you will foster a culture of learning and innovation, and discover new ways to improve.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you make kaizen activities sustainable and not just one-time events?

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3

4

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6

1 Set clear and realistic goals

2 Involve and empower your team

3 Track and measure your results

4 Review and standardize your processes

5 Seek and embrace feedback

6 Here’s what else to consider

Lean Manufacturing

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How can you make kaizen activities sustainable and not just one-time events?

1

2

3

4

5

6

1 Set clear and realistic goals

2 Involve and empower your team

3 Track and measure your results

4 Review and standardize your processes

5 Seek and embrace feedback

6 Here’s what else to consider

Lean Manufacturing

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