Kaizen (continuous improvement)
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Question
What is Kaizen?
Answer
Japanese for 'continuous improvement' — small, regular improvements by ALL workers that add up to big results over time.
💡 Hint
Continuous small improvements
Question
Three benefits of Kaizen?
Answer
Improves quality/efficiency, low cost, motivates workers (feel valued), reduces waste, teamwork culture.
💡 Hint
Quality + low cost + motivation
Question
Kaizen links to: JIT, cellular manufacturing, ___
Answer
TQM and quality assurance — all lean tools work together.
💡 Hint
TQM + QA
Question
Kaizen works best when combined with ___
Answer
Other lean tools like JIT and TQM — they reinforce each other.
💡 Hint
JIT + TQM
Question
Three challenges of Kaizen?
Answer
Slow results, needs culture shift, training required, hard to sustain enthusiasm, not for urgent large-scale changes.
💡 Hint
Slow + culture + sustain
Question
How Kaizen works?
Answer
All workers suggest improvements, changes are small/low-cost, teams meet regularly, improvements tested and measured.
💡 Hint
All workers + small + regular + tested
Question
Kaizen example: tool rack moved closer saves 30 seconds per product — ___
Answer
Small change, big impact over thousands of products.
💡 Hint
Small × many = big
Question
Kaizen = many small steps, not ___
Answer
One giant leap — progress, not perfection.
💡 Hint
Small steps
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Topic 5.3 hub
Lean production and quality management (HL only)
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