Kaizen is another idea developed in Japan. It supports lean
production by introducing the idea of continuous improvement.
Kaizen is a concept that makes improvement the responsibility of
everyone involved in production. Improving efficiency becomes a
continuous process, not a one-off activity. Kaizen implies that even
the smallest improvement should be made, as many small
improvements can lead to big savings.
Before building the new factory, Nestlé Waters used various
techniques to see where the current factory could be made more
efficient. Nestlé Waters used a lean production technique called
Value Stream Mapping (VSM). VSM illustrates the flow of materials
and information required to bring the finished product to the
consumer. Lean training sessions helped employees to determine
where the production process could be improved to reduce waste,
for example, by combining or removing elements of the process.
The outcome of the VSM at Nestlé Waters was then used to plan
the new bottling plant, ensuring the processes were as efficient as
possible. Nestlé’s commitment to the environment and sustainability
was a key factor throughout the planning process. The site for the
new factory, called Waterswallows, was a previously undeveloped
Greenfield site. Nestlé Waters worked closely with the local
community through a consultation process to ensure plans fitted in
with local community development plans. The site has great
transport links, something that was very important to Nestlé to
ensure its carbon emissions are kept as low as possible. Good
transport links are vital, both in building the new plant and in the
day-to-day running of the factory for goods in and out. The new site
is large enough to enable Nestlé Waters to expand production to
meet demand. It also allows Nestlé Waters to combine for the first
time offices, warehousing and production on one site, something
the old site did not allow due to size constraints. Bringing all
warehousing onsite saves time and reduces the need for
transporting stock, improving the site’s environmental impact.