Kaizen is always consider an opening move in the context of manufacturing in manufactory by business managers . Kaizen transformed the exemplar of not only in Japan but also in all parts of the world . Practising Kaizen result in minimizing waste action , meliorate effectiveness , enhanced customer service , improved employee booking . Kaizen enable system cater to the ever - rise demands of delivering more to the client and at the same time run through less resources . Kaizen is not only about the surd welfare . It contribute in a cultural change of uninterrupted improvement involve all tiers of employees .
The Kaizen political orientation is being adapted and practiced by all business concern sector around the world be it Discrete Manufacturing , Process industries , Service Industries , Hotels , Hospitals , Governments and the lean can go on . Hence , there are no surprises that the Farming Industrytoo joined the elite club of Industries that adapt and practice Kaizen . Thus , “ factory ” and “ farm ” are not different any longer . Whetherone produces “ fancy - cars ” or “ flush ” , the business practices adapted by both the business concern managers are one and the same . Just as it go on with other industries , Kaizen help Farms develop , practice and sustain their objectives of becoming effective and productive in all the tasks it performs . The tasks in a typical Farm industriousness are : planting , irrigation , ethnic action , harvest home , transporting , class & sizing , packing , storing , despatch & distribution etc .
Kaizen is not practice purport at financial gains though , invariably , all entrepreneurs appear for it . Financial gain is a by - product of practicing Kaizen . The cultural translation hap in the organization is the main takeout . The typical areas where one can visually see theimprovements in Farms are :
Kaizen think Change for best - Every day , Everywhere and Everybody . If the improvement is not happening every day , not involving everybody and not happen everywhere , then it is not Kaizen . This differential feeler makes Kaizen unique be it in farms or in factories . As to bring out a change , a modification in the mind - set is essential . Kaizen principle are being accommodate by farm that result in a remarkable improvement in their business , behaviour and actions .
client orientation : Every business survives on provide to its client ’ needs . Kaizen emphasise on providing time value to the client . constantly , every customer prefer three factors as Value – Quality , Cost and Delivery . These could be achieved by delivering what the customer wanted , at the time he wanted and in the amount they wanted . Providing time value to international client are easy if we provided value to internal customers ( next process ) .
People orientation : If we have to get the best of the processes , we need to build the mass accordingly because it is the people who do the processes . The winner of Farms lies in the hands of the workers . Kaizen insure that people from all level participate and contribute . People are not problems but are trouble - solvers . In Daily Kaizen , people from all level participate , portion out their concerns , identify the causes and also implement the rejoinder measures . This enables removal of find fault culture and everyone owns answerableness .
Workplace orientation : An organized work is the instauration for every continuous improvement initiative . alteration initiatives should always begin with the work because the surround influence the hoi polloi ’s thinker . 5S is the foundation stone that has five pillars — Sort , fit in orderliness , Shine , Standardize , and ego - subject . The whole exercise begins with Sorting . This intend removing the unwanted item from the farm . Any item that is not used on a regular basis or that does not sum any time value to the process or client has to be fling straightaway . Farms have benefit by make blank space that can be used for tame thus converting an unused land to a rich force field .
place - in - order commend taxonomical arrangement . well-off tostore and easy to retrieve . This eliminates search time andthis time can be used productively . There are linguistic rule to followthis .
The third pillar is Shine . keep the farm unclouded . cleansing has to be done every day – cleaning of workplace stations , pumps , shredder , compressor , tool , farm - orbit . cleanup done form the inspection view . It is because when we audit , we detect ; when we detect , we correct it . Thus , cleaning leads to rectification . clean the farm costless from unwanted chemical , plastics etc will aid in the long run .
Fourth pillar is Standardization . standardization make it mere and easy to conform to . All the activities are to be standardised . 5th pillar is ego - subject field or do - it - by - yourself . Periodical audit , ego - audit , pillar - head audits inform us where we were and where we are .
In a vast open area describe the freakishness is tough . Visual Management helps here . For example , during field study if the worker found any pest & disease related consequence on the stems , they can put a flag ( with semblance codes ) highlighting the pip - sprayers to work on the same . Fertigation details with ticker and blocks neatly mapped help the workers to identify and trouble shoot . Schedule of the cultural activities on each block made seeable in front of the block help them watch over the same .
Process orientation : Kaizen assert on tag the operation and the solution because a correct process would bring in the results repeatedly . It is not about achieve it somehow but doing it in a certain way which is the Kaizen way !
Everywhere the right physical process has to be adapt as to get the right results . Kaizen practicing farms emphasise their employee on this and insure the correct cognitive process are adhered . Kaizen insists on Value Stream Organization ; also can be termed as farm - within - farms . If rose are one character of craw , then the field from which roses are produce , the team that pack roses , the squad that moves roses and ships rose are club together and work as Roses Team . This ease better communication between the processes and enables rapid trouble - shot . Immediate feedback regarding the pests & diseases , infected theme , overt - bud are communicate to field team who can correct such mistake in their next cultural activities .
farm too have maintenance action . Pump rooms , compressors , shredders , lighting personal credit line , workstation design , irrigation lines & statistical distribution , upkeep of tractors , transport vehicle and the list goes on . Autonomous Maintenance enhances the life story of the spares , increases the life of the brand in shredders that ensue in energy - economy ; just arresting the leak from all the irrigation occupation lead to save of 6 hours of pumps running in one of the farms per Clarence Day .
Scientific predilection : As to insure the ripe menstruum , one has to abide by the process and look for wastes or non - value adding activities . Waste is not the problem per se , but are the symptoms of the existing problem . Elimination of waste absolve the content . If we are eliminating non - value supply activities that results in wastage of 1 time of day a day , would economize the farms 37 piece of work - days in a class . advance by cut – this is what Kaizen prescribes . Wastes classified as 8 types have to be downplay or eliminated – they are : Defects , Over processing , Waiting , fresh skills , Transportation , Inventory , Motion and Excess yield .
Systematic approach : apply DoE on the block size , number of beds per closure , length of the bed , plant per bed , stem per plant result in saving of almost 140 acres of estate for one of our client . This is a staring illustration of stating Waste equals free mental ability .
Where is the money?Kaizen is not practiced for money , though , business players look for it – where is the redundant money ? Or in other words , where have we trim back the special money ? A 5 % saving from a farm every yr for a decennium , the stage business is produce up by 50 % which is a noteworthy growth for any variety of farm .
Kaizen approach is not about get with child and prominent by years but about becoming more efficient , effective , establishing adept processes , authorise employee etc . , The business can be grown by being more in effect and efficient by delete the non - value adding activities . This has work well for many farm and will work for others too . distinctive Results Table : ( Results experienced by Flower Farm who practiced Kaizen with our guidance for 3 years and still continuing )
All these results are proven , however , will depart from Farm to farm , craw to craw and the manner in which Kaizen is being deploy . The biggest advantage with practicing Kaizen is , even if we apply it wrongly , we would get benefits . At the end of the day , Excellence is allabout perennial pursuance of ne plus ultra . This journey of Excellence never stop , we keep better every sidereal day when it is practiced by everybody and everywhere .
For more informationKaizen InstituteNarasimhan GopalakrishnanEmail:[email protected]www.kaizen.com
