Methods of kaizen

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Copyright 2007 – Biz/ed
Production Methods & Kaizen

Production Methods

Efficiency
• Any production method relies on efficiency –
this can be viewed in different ways:
• Productivity – a measurement of output per
unit of the factor used (labour, capital or land)
Total Output
Productivity = -------------------
Units of Factor
• Technical Efficiency – output produced
using the fewest possible inputs
• Productive Efficiency – output produced at
the lowest possible cost

Efficiency
• Production decisions involve deciding
methods for new production runs and
analysis of existing methods.
• Decisions may include:
– Substitute machinery for labour?
– Use of new technology?
– Organisation of the production layout?
– Change of production method?

Production Methods
Copyright: Photolibrary Group
Whilst all output can be
classed as production,
different production
methods may be more
appropriate for different
products or services.
Agriculture tends
to be very land
intensive –
efficiency could
be measured in
terms of output
per acre/hectare

Production Methods
Copyright: iStock.com
As technology and
analysis of production
methodology has
improved, methods
have changed
dramatically – what
used to be labour
intensive production
methods are now
capital intensive

Production Methods
California Oil is Source of Wealth and Fear
Copyright: iStock.com
Textile factory
Copyright: Stock.Xchng
Bottle production line
Copyright: Photolibrary Group
The choice of
production method
and the factor
inputs depends on
such things as:
• the nature of the
product
• factor costs
• the scale of
production

Production Decisions
Which method? Type of Product
One-Off Order?
Mass Market product?
Batch?
Market size and
Segment
Factor Costs –
Land, Labour and
Capital
Complexity of design

Production Methods
• Job Production – One-off production -
each item might have particular
specifications
• Flow Production – suitable for mass
market products that are identical
• Batch Production – each stage of the
production process has an operation
completed on it before moving on to the
next stage – allows modifications to be
made to products that otherwise are
the same

Production Methods
Which is more efficient?
Operation 1 2 3 4 5
6
7
891011
Finished
Product
This?

Production Methods
Operation 1
1a 1b 1c 1d
2a 2b 2c
3a 3b 3c 3d
4 Finished
product
Or this?

Production Methods
Or this?
Cell 1 Cell 2 Cell 3
Finished Product Finished ProductFinished Product

Production Methods
• Answer – it could be any of them!
• The design of the production space
can influence:
– Output levels
– Factor use
– Efficiency
– Cost levels
– Quality assurance procedures

Kaizen (Continuous Improvement)

Kaizen (Continuous Improvement)
• Japanese concept – not made
redundant by the decline of the
Japanese economy which may be due
to other institutional factors!
• Focus on gradual and continuous
improvement
• A whole business philosophy
• Importance of EVERYONE buying into
the concept and the vision

Kaizen
• Great attention paid to
customer requirements
and needs
•Efficient stock
control methods help
reduce costs and
improve cash-flow
•Flexible working
practices and
empowerment – help
increase efficiency,
reduce costs and
improve motivation
•Leadership seen as vital.
Ability to communicate a
clear vision, take people
along with the vision and
to think about where the
company needs to be in
5, 10, 15 and 20 years
time
•Fundamental principles –
often characterised as ‘lean
production’ – reducing waste,
zero defects, high quality
control measures at all stages•Punctuality in all aspects – delivery,
supply, manufacture, etc.

Quality Assurance
• Six Sigma Methodology
– Coined by Motorola Engineer Bill Smith
– Now a major influence on production
methods and quality assurance
– Data and statistical driven approach to
eliminate defects in production
– Aims to improve processes and reduce
variations in quality
– Necessitates organisational change, training
and planning

Methods of kaizen

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