Metal Fabricators Using Gemba Kaizen

Gemba Kaizen Defined

Gemba Kaizen Defined

Kaizen is a Japanese term signifying "continuous improvement." It focuses on incremental changes for continual improvement in a company. The minute alterations happen over time instead of focusing on one significant alteration that occurs sporadically and hopes for an extreme improvement. Kaizen dictates that human resources are the most considerable facet of a company. Additionally, a wild change does not instill success as well as small alterations that are conductedcontinuously. Finally, Kaizen says that improvements have to be rooted in numbers and statistics developed from the processes in a business.

Gemba is an additional Japanese term, which means "real place." When talking of Gemba Kaizen, it is referring to the shop floor or wherever the work is taking place. It also handles eliminating, finding, and reducing any inconsistencies within an organization.

Principles of Kaizen

To put Kaizen into practice, a team has to be established that learn the principles of Kaizen and will observe the workplace. There are five main principles in Kaizen. The first point is the promotion of teamwork. The second is that staff have to be disciplined on a personal level. The third point is that morale needs to be boosted in the work setting. The fourth principle is regarding groups of people who meet to discuss quality issues, or quality circles, and the last point involves any suggestions for improvement and growth, and can come from any member of a quality improvement team.

Kaizen Implemented

One aerospace metal producer took a Gemba Kaizen class and also obtained consulting from a company providing these services. The company's aims were to grow earning by growing their sales and lowering the costs of operating the business. The places they needed to tackle in order to reduce costs were space availability, productivity of their labor force, and inventory. After the workshop, the organization was able to reduce their space needs by more than 5,000 sq ft, reduce manufacturing lead-times by over 23%, grow their sales, and their yearly return on investment for the lean consulting was over 5 to 1. The workshop and consulting paid for itself in the benefits that were found from the Gemba Kaizen strategies.

Kaizen Applied

Our metal manufacturing organization, Maloya, used Kaizen through a sequence of steps. They made efficiency metrics to measure performance in their work areas for production. They also conducted measurements of production quality methods in addition to benchmarking of the needed skill sets for workers in the many work sites at Maloya. This allowed them to find which of their staff memberswould benefit from subsequent training.

Benefits of Kaizen

Benefits of implementing Kaizen include the recognition of problems right at where they start so that they can be fixed at the root. Small improvements can result in larger gains for the business. Advancements in the quality of products and prices will make clients happier and then business will grow due to the customers who are happy with their purchase. Instilling employee involvement in the advancement of the organization makes them feel a part of the whole process and they are happier to be at work. There are many chances to use Kaizen, and implementing it in a metal manufacturing setting can provide substantial rewards.

by: Marc Anderes.

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