Gemba Kaizen : a Commonsense Approach to a Continuous Improvement Strategy

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The definitive, fully up-to-date guide to continuous improvement in the workplace

"An updated version of a classic book that shares a wealth of new healthcare examples and case studies from around the world. The methods in this book will help you improve quality and safety, reduce waiting times, and improve the long-term financial position of your organization. Highly recommended!" --Mark Graban, author of Lean Hospitals and coauthor of Healthcare Kaizen

"Every business faces the iron triangle of quality, cost, and delivery. Conventional thinking claims you cannot have all three. Not only does Mr. Imai turn that thinking on its head, but he shows you exactly how to do it." -- Matthew E. May, author of The Elegant Solution and The Laws of Subtraction

"Masaaki Imai has done it again. The second edition of his famous book not only describes all the tools necessary for any type of business to implement a lean strategy but also includes a large number of excellent case studies." -- Art Byrne, author of The Lean Turnaround

Written by Masaaki Imai, pioneer of modern business operational excellence and founder of the Kaizen Institute, Gemba Kaizen , Second Edition is an in-depth revision of this renowned, bestselling work. The book reveals how to implement cost-effective, incremental improvements in your most critical business processes. Global case studies from a wide range of industries demonstrate how gemba kaizen has been successfully used to:

Maximize capacity and reduce inventory at Unga Limited, one of Kenya's largest flour-milling operations Change the IT culture at Achmea, a large European insurance firm Exceed customer expectations at Walt Disney World in the United States Improve quality at Inoue Hospital in Japan Transform retail processes at Sonae MC, Portugal's largest employer Practice daily kaizen at Tork Ledervin, a weaving plant in Brazil Stamp out muda at Sunclipse, an industrial packaging distributor in the United States Manage quality improvement by total workforce involvement at Xuji Group Corporation, an electrical manufacturer in China Implement gemba kaizen at many other companies worldwide

To thrive in today's competitive global economy, organizations need to operate more effectively and profitably than ever before. Developing problem solvers, increasing productivity, improving quality, and reducing waste are essential success factors. Proven strategies for achieving these goals are included in this pioneering guide.

This comprehensive resource offers detailed coverage of important gemba kaizen topics, including:

Quality, cost, and delivery in the gemba The five steps of workplace organization Identifying and eliminating muda--any non-value-adding activity Visual management Supervisors' roles in the lean workplace Gemba managers' roles and accountability in sustaining high performance Just-in-time and total flow management The CEO's role in leading a kaizen culture

The methods presented in Gemba Kaizen , Second Edition reveal that when management focuses on implementing kaizen (incremental, continuous improvement) in the gemba (the worksite) unique opportunities can be discovered for increasing the success and profitability of any organization.

Author Notes

More than any other business authority in the world, Masaaki Imai has championed the concept of kaizen over the past three decades in thought, word, and action. He is considered one of the leaders of the quality movement and a pioneer of modern business operational excellence. Mr. Imai is an international lecturer, consultant, and founderof the Kaizen Institute, a leading continuous improvement consultancy with offices worldwide. Mr. Imai's first book, Kaizen --translated into 14 languages--is the authoritative reference on the subject. In 2010 he was honored for his lifetime of achievement with the first ever Fellowship of Quality Council of India.

Preface	p. xiii
Acknowledgments	p. xvii
About Kaizen Institute	p. xix
Chapter 1 An Introduction to Kaizen	p. 1
Major Kaizen Concepts	p. 2
Kaizen and Management	p. 3
Process versus Result	p. 4
Following the PDCA/SDCA Cycles	p. 4
Putting Quality First	p. 6
Speak with Data	p. 7
The Next Process Is the Customer	p. 7
Major Kaizen Systems	p. 7
Total Quality Control/Total Quality Management	p. 8
The Just-in-Time Production System	p. 8
Total Productive Maintenance	p. 9
Policy Deployment	p. 9
The Suggestion System	p. 10
Small-Group Activities	p. 10
The Ultimate Goal of Kaizen Strategy	p. 11
Chapter 2 Gemba Kaizen	p. 13
Gemba and Management	p. 14
The House of Gemba	p. 19
Standardization	p. 19
The Five S (5S) of Good Housekeeping	p. 21
Muda Elimination	p. 21
The Golden Rules of Gemba Management	p. 23
Go to the Gemba First	p. 24
Check the Gembutsu	p. 28
Take Temporary Countermeasures on the Spot	p. 29
Find the Root Cause	p. 30
Standardize to Prevent Recurrence	p. 31
Application of the Golden Rules	p. 33
Chapter 3 Quality, Cost, and Delivery at the Gemba	p. 37
Quality: More Than Just a Result	p. 37
Quality Management at the Gemba	p. 40
Cost Reduction at the Gemba	p. 44
Improve Quality	p. 45
Improving Productivity to Lower Costs	p. 45
Reduce Inventory	p. 45
Shorten the Production Line	p. 46
Reduce Machine Downtime	p. 46
Reduce Space	p. 47
Reduce Lead Time (Throughput Time)	p. 47
Role of the Gemba in Overall Cost Reduction	p. 48
Delivery	p. 48
Quality Improvement and Cost Reduction Are Compatible	p. 49
Chapter 4 Standards	p. 51
Maintain and Improve Standards	p. 51
Operational Standards	p. 53
Key Features of Standards	p. 54
Toyoda Machine Works	p. 57
The Kaizen Story	p. 57
The Toyota Business Practice: The Standard Problem-Solving Story at Toyota	p. 58
Kaizen and International Quality Standards	p. 61
Chapter 5 The 5S: The Five Steps of Workplace Organization	p. 65
Good Housekeeping in Five Steps	p. 66
5S for the City: Civic Pride in Romania	p. 67
A Detailed Look at the Five Steps of 5S	p. 69
Seiri (Sort)	p. 70
Seiton (Straighten)	p. 72
Seiso (Scrub)	p. 74
Seiketsu (Systematize)	p. 75
Shitsuke (Standardize)	p. 75
Introducing 5S	p. 76
Chapter 6 Muda	p. 79
Muda of Overproduction	p. 80
Muda of Inventory	p. 82
Muda of Defects	p. 82
Muda of Motion	p. 83
Muda of Processing	p. 83
Muda of Waiting	p. 84
Muda of Transport	p. 84
Muda of Time	p. 87
Categorizing Muda in the Service Sector	p. 87
Muda, Mura, Muri	p. 90
Mura (Variation)	p. 90
Muri (Overburden)	p. 90
Removing Muda from Public-Sector Organizations	p. 91
Chapter 7 The Foundation of the House of Gemba	p. 95
A Learning Enterprise	p. 96
Suggestion System and Quality Circles	p. 99
Building Self-Discipline	p. 100
Chapter 8 Visual Management	p. 103
Making Problems Visible	p. 103
Staying in Touch with Reality	p. 104
Visual Management in the Five Ms (5M)	p. 106
Manpower (Operators)	p. 106
Machines	p. 107
Materials	p. 107
Methods	p. 107
Measurements	p. 107
Visual Management to Manage Complexity	p. 108
Visual Management with 5S	p. 109
Posting Standards	p. 110
Setting Targets	p. 111
Chapter 9 The Supervisors' Roles in the Gemba	p. 113
Training Within Industries	p. 113
Managing Input (Manpower, Materials, and Machines)	p. 117
A Day in the Life of a Supervisor at Toyota Motor Manufacturing Kentucky	p. 120
Morning Market (Asaichi)	p. 126
Best-Line Quality-Assurance Certification	p. 130
Defining Challenges	p. 132
Pseudomanagerial Functions of Supervisors in the Gemba	p. 132
Chapter 10 Gemba Managers' Roles and Accountability Kaizen at Toyota Astra Motor Company	p. 135
Role Manuals at TAM	p. 136
TAM Group Leaders' Responsibilities	p. 139
TAM Foremen's Responsibilities	p. 140
TAM Supervisors' Responsibilities	p. 140
Items That Need to Be Managed in the Gemba	p. 141
Group Leaders' Daily Schedule of Activities: Examples from the TAM Manual	p. 142
Group Leaders' Activities: Production, Cost, and Quality Examples from the TAM Manual	p. 143
Foremen's Activities: Cost-Reduction Examples from the TAM Manual	p. 145
Supervisors' Activities: Personnel and Training Examples from the TAM Manual	p. 146
Section Managers' Roles and Accountabilities: Examples from the TAM Manual	p. 148
The Conditions Necessary for Successfully Defining Roles and Accountability at TAM	p. 148
Staff Development	p. 149
On-the-Job Training	p. 149
Formal Classroom Training	p. 150
Voluntary Activities	p. 150
The Identification of Potential Problems	p. 150
Hiyari Reports	p. 150
Training in the Anticipation of Problems	p. 151
The Benefits of Kaizen at Toyota Astra Motor Company	p. 151
Chapter 11 From Just-In-Time to Total Flow Management	p. 153
Just-In-Time at Aisin Seiki's Anjo Plant	p. 154
Takt Time versus Cycle Time	p. 156
Push Production versus Pull Production	p. 157
Establishing Production Flow	p. 158
The Introduction of JIT at Aisin Seiki	p. 160
The First Step of Kaizen at Aisin Seiki	p. 161
The Second Step of Kaizen at Aisin Seiki	p. 162
Spreading the Benefits of JIT to Other Industries	p. 163
Total Flow Management	p. 164
TFM Transformation in Company A	p. 167
Chapter 12 Just-In-Time at Wiremold	p. 183
Chapter 13 The CEO's Role in Kaizen	p. 195
Chapter 14 Going to the Gemba	p. 205
Gemba Kaizen and Overall Corporate Kaizen Two-Day Kaizen	p. 207
Checklists as a Kaizen Tool	p. 210
Gemba Kaizen Workshops	p. 211
Case Studies	p. 217
Lessons from a 20-Year Kaizen Journey	p. 219
Changing the IT Culture at Achmea	p. 225
Daily Kaizen at Tork Ledervin	p. 229
Kaizen in Public Spaces: Transforming Rome's Airports	p. 233
Sonae MC: The Silent Revolution	p. 239
Surpassing Expectations through Kaizen at Embraco	p. 249
Kaizen at Oporto Hospital Centre: Making Patient-Centric Care A Reality	p. 261
Kaizen Enables Innovation and Customer Intimacy at Densho Engineering	p. 269
Kaizen Enables Innovation and Customer Intimacy	p. 273
Cutting Red Tape at a Public Utility: Enexis	p. 275
People Power: Participation Makes the Difference for Electrical Manufacturer in China	p. 279
Rossimoda: Kaizen and Creative Product Development	p. 283
Finsa Uses Kaizen to Emerge Stronger from a Crisis	p. 293
Innovating with Kaizen at Group Health	p. 301
Kaizen Helps Caetano Bus Deliver on Schedule	p. 307
Kenyan Flour Producer Uses Kaizen to Increase Capacity, Improve Efficiency	p. 313
Kaizen as the Foundation for Innovation at Medlog	p. 317
Growing with Kaizen at Supremia	p. 323
Exceeding Customer Expectations at Walt Disney World	p. 329
Kaizen Experience at Alpargatas	p. 335
Transforming a Corporate Culture: Excel's Organization for Employee Empowerment	p. 345
Quality in a Medical Context: Inoue Hospital	p. 353
The Journey to Kaizen at Leyland Trucks	p. 359
Tightening Logistics at Matarazzo	p. 369
Stamping Out Muda at Sunclipse	p. 373
Housekeeping, Self-Discipline, and Standards: Tokai Shinei Electronics	p. 381
Solving Quality Problems in the Gemba: Safety at Tres Cruces	p. 389
Glossary	p. 397
Index	p. 407
Worldwide Contact Information for Kaizen Institute Consulting Group	p. 423

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