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Gemba Kaizen: A Commonsense, Low-Cost Approach to Management »

Book cover image of Gemba Kaizen: A Commonsense, Low-Cost Approach to Management by Masaaki Imai

Authors: Masaaki Imai
ISBN-13: 9780070314467, ISBN-10: 0070314462
Format: Hardcover
Publisher: McGraw-Hill Companies, The
Date Published: March 1997
Edition: (Non-applicable)

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Author Biography: Masaaki Imai

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Book Synopsis

When it comes to making your business more profitable and successful, don't look to re-engineering for answers. A better way is to apply the concept of kaizen, which mean making simple, common-sense improvements and refinements to critical business processes.The result: greater productivity, quality, and profits achieved with minimal cost, time, and effort invested. In this book, you discover how to maximize the results of kaizen by applying it to gemba—business processes involved in the manufacture of products and the rendering of services—the areas of your business where, as the author puts it, the "real action" takes place.

Publishers Weekly

Rarely can an author take credit for changing the way business works, but Imai did just that in 1986, in his native Japan, when he wrote Kaizen (Japanese for "continuous, incremental improvement"). As a result of that book, thousands of businesses made incremental improvement a daily goal. Here, in this straightforward sequel, Imai shows exactly how kaizen should be implemented. The starting point, he argues, is at the gemba ("the place where the real work is done"). The gemba could be the assembly line in a manufacturing plant, or, at a service company, where employees interact with customers. Wherever it is, though, it is definitely not behind a manager's desk. Imai identifies the three major steps in implementing kaizen at the gemba: pay attention to housekeeping (keeping only your necessary tools nearby); eliminate waste (everything from overproduction to defective quality); and standardize (make sure the improvements in the first two steps are carried on indefinitely). The roles for line workers, managers and chief executives are also detailed here, as are numerous case studies that help bring this thought-provoking book to life. (May)

Table of Contents

Foreword
Preface
Acknowledgments
Glossary
Ch. 1An Introduction to Kaizen1
Ch. 2Gemba Kaizen13
Ch. 3How to Manage Quality, Cost, and Delivery in Gemba37
Ch. 4Standards51
Ch. 5The 5 S's: The Five Steps of Housekeeping63
Ch. 6Muda75
Ch. 7The Foundation of The House of Gemba87
Ch. 8Visual Management95
Ch. 9Supervisors' Roles in Gemba105
Ch. 10Gemba Managers' Roles and Accountability: Kaizen at Toyota Astra Motor Company125
Ch. 11Just-in-Time: The Ultimate Production System145
Ch. 12Just-in-Time at Wiremold159
Ch. 13Going to Gemba: Two-Day Gemba Kaizen and Overall Corporate Kaizen171
Case Studies185
MK Electronics Company185
Exceeding Customer Expectations at Walt Disney World189
"The Press Came Down Twice!": 5S and Safety at a Press Shop195
Housekeeping, Self-Discipline, and Standards: Tokai Shin-Ei Electronics199
The Answer was in the Files: Gemba Kaizen in R&D209
How 5S at a Die Plant Eliminated the Need to Relocate211
Cleanliness is Key at Daiwa Jitsugyo215
Stamping Out Muda at Sunclipse219
Transforming a Corporate Culture: Excel's Organization for Employee Empowerment227
The Journey to Kaizen at Leyland Trucks237
Always Learning at Lobro249
Adapting to Market Changes: Siemens Oostkamp257
Solving Quality Problems in Gemba: Safety at Tres Cruces263
Quality in a Medical Context: Inoue Hospital273
Tightening Logistics at Matarazzo281
Kaizen Experience at Alpargatas285
Keeping an Eye on the Data: Infotec295
Support from Top Management: Fidelity Investments301
A Focus on Training: Kaizen at Lucas Automotive313
Kaizen at an Insurance Company: La Buenos Aires323
Kaizen at "Company A" in Europe331
Index343

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