What is the kaizen method?
The kaizen method originates from Japan and literally means "change for the better". In practice, it means small, incremental improvements that have a big impact over time. The power of kaizen lies in the daily commitment of employees at all levels to improve processes, tools and workplaces. No major revolutions, but evolution. Continuously and with the involvement of everyone.
Multitube offers solutions that support this way of thinking and working: flexible, adaptable and focused on eliminating waste, one of the central goals within the kaizen method.
The principles of the kaizen method
The kaizen method is all about creating a working environment in which everyone, every day, at every level is involved in improving processes. It is based on five fundamental principles:
- Improve a little every day - continuous small adjustments pay big dividends in the long run.
- Involve everyone - from operator to management, everyone has valuable input.
- Focus on processes - improve to management, everyone has valuable input.
- Use data and facts - improvements are based on observations, measurements and analysis.
- Work on standardisation - each improvement becomes the new standard, as a basis for further optimisation.
These principles ensure that the kaizen method is not a project with an end, but a culture of ongoing development.
The 6 steps of the kaizen method
To get from ideas to sustainable improvement, the kaizen method is often applied through these six clear steps. They help to improve in a systematic, factual and result-oriented way. Multitube provides support at each step with smart workplace solutions and logistical tools.
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Identify the problem
Improving starts with identifying a bottleneck. This could be a deviation in the process, such as too long a cycle time, an ergonomic problem, many errors or an inefficient material flow. Wastages (such as overproduction or unnecessary movements) are also revealed here.
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Measure the facts
Improvements are not based on gut feelings, but on facts. In this phase, you collect data: how often does the problem occur? What are the lead times? How many mistakes are made? Measure objectively and accurately.
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Analyse the facts
What is the cause of the problem? Use tools like the 5xWhy method or fishbone diagrams to get to the heart of the matter. Also look at the workplace: how is it set up? Is there unnecessary handling, reaching, walking or searching?
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Generate improvements
Together with the team, come up with solutions. Small changes, such as a work table at the right height, a different walking route, or adding a roll-through shelving unit can make all the difference. The goal: less waste, fewer errors, more flow.
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Implement improvements
Implement the chosen improvements, preferably on a small scale first, so that the effect can be properly measured. Make the change visible and make sure employees are properly involved.
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Check and secure
Is the improvement working? Has performance improved? And more importantly, will the new way of working be maintained? What works well should be secured in standards, work instructions and visual aids.
The kaizen method as part of lean production
Within Lean production, the kaizen method is an indispensable part. Lean is all about creating maximum value for the customer with as little waste as possible. That means: eliminating waste in time, material, movement and space.
Multitube perfectly matches this with a wide range of products designed to support Lean working:
- Work tables that adapt to changing processes or ergonomic requirements.
- Andon systems that provide instant insight into deviations or stoppages.
- Roll-through racks that ensure a streamlined supply of materials.
- Order pickers that speed up and optimise internal logistics.
- Modular workstation equipment that can constantly grow with the process.
These solutions make it possible to successfully embed the kaizen method in daily operations.
Workstations: the basis for continuous improvement
A well-equipped workstation is the starting point of any kaizen improvement. Multitube develops and supplies workbenches that are fully customised for the user and the process. Examples include:
- Adjustable workbenches with electric or manual height adjustment
- Ergonomically designed workstations with space for tools, documentation and visual instructions.
- Modular tables that can be easily adapted in case of process changes.
Optimally designing workstations according to kaizen principles, such as visual control and ergonomics, increases efficiency and reduces the risk of error. Exactly what the kaizen method is all about.
Andon systems: visual management in action
Andon is a visual tool that makes deviations in the process immediately visible. Whether it is a malfunction, material shortage or quality problem, andon signals make it possible to intervene quickly. Andon systems can easily be added to Multitube's work tables.
Andon reinforces visual management, a core element within the kaizen method. By making problems immediately visible, it becomes easier to analyse them and solve them in a targeted way.
Flow racks: speeding up material flow
Flow racks, also known as flow racks, are essential within Just-in-Time (JIT) and First-In-First-Out (FIFO) systems. They use gravity to automatically roll totes or boxes to the front position. This means:
- Support Just-in-Time delivery
- Minimise walking routes
- Promote FIFO principle (First-In, First-Out)
Flow racks, or kanban racks, contribute to efficiency, safety and structure on the shop floor. They are easy to integrate into the work process and can be adjusted quickly. An ideal tool for those working according to the kaizen method.
Order pickers: smart internal logistics
Within Lean production and the kaizen method, everything revolves around smart use of materials and efficient transport. Multitube picking trolleys have been specially developed for this purpose. These trolleys ensure that materials are available at exactly the right time and place. If you want to improve your employees' ergonomics even further, go for an picking cart with electric drive.
Benefits of order pick trolleys:
- Reduction of walking distances
- Better ergonomics
- Always adaptable to changing production needs
By using modular order picker carts, companies can optimise their internal logistics and easily adapt to changing production needs - an important element within a kaizen strategy.
Workstation design & warehouse solutions: flexibility as a kaizen tool
The kaizen method requires an environment that is flexible, visual and efficient. Multitube offers a complete range of workplace equipment and warehouse solutions that allow organisations to continuously adapt and improve their processes. Examples include:
- Modular storage systems
- 5S workstations
- Lean trolleys
These solutions are designed to grow with the process. They support the principle of small adjustments with big impact, the heart of kaizen.
5S method as the foundation for kaizen
The 5S method - Sort, Arrange, Clean, Standardise and Maintain - is often the first step within a kaizen process. This approach helps to create a structured, safe and orderly workplace.
Multitube makes implementing 5S easy with visually structured workstations and storage solutions. Colour coding, labelling and modular elements make it possible to quickly implement and maintain improvements.
Multitube and kaizen: an ideal combination
Multitube not only supplies products, but also thinks along with the process. By looking together with customers at workflows, ergonomics and stock management, Multitube helps design a production environment that does justice to the kaizen method.
The advantages of Multitube solutions for kaizen at a glance:
- Modular and scalable: always adaptable to new insights
- Lean and visual: support of 5S, JIT and andon
- Ergonomic: increases comfort and reduces physical strain
- Support with implementation: from design to execution
Conclusion: The kaizen method in motion with Multitube
The kaizen method is not a one-off change, but a way of life within the organisation. By continuously improving workplace design, material flows and visual management, companies can structurally increase their efficiency, safety and quality.
With solutions such as work tables, andon systems, flow racks, order pick carts and other modular workplace and warehouse solutions, Multitube supports organisations in every step of their kaizen journey.