Table 2 : effects on thinking: target vs process approach
The Japanese have been farmers for 50 years , so easily one can understand their devotion
and discipline on continuous improvement way of thinking and living (11) .The implementation
www.michailolidis.gr 6
of Kaizen principles has been viewed as one of the key factors to Japanese competitive
success. Kaizen then has emerged in the U.S. as a methodology leading to dramatic
increases in productivity by manufacturing companies
Process quality improvement needs the use of specific tools and techniques to be introduced
and supervisors and operators to be trained on. Appendix 2.1 contains examples of continuous
improvement tools, the ,so known as ‘9 Tools‘, such as : process flow charts, Pareto analysis ,
run charts, data collection, histograms, scatter analysis,checklist ,a cause and effect diagram,
control charts, that used by the teams to detect problems , facilitate processes and implement
proposals (12) .
The role of visual management as a concept, practice or tool is promoted in Kaizen through
individuals or teams to help people identify problems or promote empowerment. The practice
of visual management involves the clear display of tangible objects (gembutsu), charts, lists,
records of performance, so that both management and workers are continuously reminded of
all the elements that make the Visual controls make it easy for everyone to identify the state of
a normal or abnormal condition, thus providing operators and management visibility into
performance (see Appendix2.2) Visual controls tracking performance should capture the team
effort rather than the individual. Visual controls usually lead to visual management, which can
be particularly efficient if it is used adequately to replace the bureaucratic monitoring systems
that many companies employ in order to maintain control and attempt to prevent anything from
going wrong. Visual controls must be relevant, easy to understand by the people performing
the task being measured, and must emphasize proactive actions, rather than blaming ,so the
visual workplace will: (13).
• improve safety
• make critical information available at a glance
• gain immediate measurable results including: reduced floor space, decreased process
time and machine down time
• keep everyone informed of production schedules, daily attendance, inventory levels,
etc.
• reduce search time by as much as 50%
• reduce inventory as much as 10% to 30%
• raise morale and on-time delivery