Followings are the steps of Kaizen. These steps are relevant to each other and very important for successful implementation.
1)Problem definition based on prioritization.
Selection of problem is very important to do improvement. It should be based on prioritization. Most of the time we use Pareto diagram. By using Pareto,we could measure the severity of problem. When we select any problem, we should know the target to achieve. By eliminating selected problem,how much improvement will happen in regards to key performance indicator should be known. After selection of problem,we have to define the problem. To define the problem,most common tools is 5W1H(Asking question to related to problem). 5W1H (What,Where,When,Which,Who and How Much)
2) Identification failure Mode.
While Defining a problem,we will understand the features of problem. subsequently We come to failure mode. Earlier we define problem at broad level,but when we understand the working principle we will come to know about one or more failure modes. Failure is more specific than earlier problem definition. It gives micro level failure of machines or process.3) Root cause Analysis.
Root Cause analysis is very important step of Kaizen Implementation. If problem is sporadic in nature,we should use "5 WHY" analysis for all failure mode identified.
If problem is chronic in nature we could use fish-bone diagram.
Level of analysis where we should have to implement countermeasure called as a Root Cause.
When we got correct root cause half problem got solved. After identification of root cause,we have to define the idea which will arrest the root cause for its recurrence.So idea should be always opposite to root cause. Unless idea is opposite to root cause,problem will not solved fully. If different failure has different root cause we have to identified ideas against all root causes.
Example of Root cause Vs Idea.
Root Cause Vs Idea
Long Vs Short
Open Vs Closed
Manual Vs Automatic
5) Implementation of Idea.
After identification of idea,we have to implement ideas against all root cause. Actions against root cause which will avoid the recurrence of root cause called as a countermeasure. Sometimes implementation is easy but similarly it is difficult for some ideas.
Checking result for sufficient time is also required to know all the possibility of failures of idea implementation in all variations during different product range. Normally we should check the result for next six month after implementation of idea. We have to act on variation occurred during different product change.
7) Implementation of sustainable action to maintain result.
After successful implementation of idea and its result checks,we have to identify the various actions which will keep idea implementation for lifetime. That actions either will get added in operator daily check sheet or will get added in preventive maintenance check sheet. Sometimes we have to change Standardized operating procedure to meet new process requirement. During all Steps we have to involve operator so that he/she will know the importance of every sustenance action.
8) Implementation of Same idea on other Location.
Most of the time we are facing similar problem on all similar machine so implementation of same idea on all similar machine will gives quick result without doing much effort. So we should implement same idea on similar machines.
As we know that implementation of idea is not that much simple,it incurred cost so we need to check return on investment in terms of cost. This improves confidence of management on improvement teams.