Among the Lean methods that can be mentioned, Kaikaku is often presented as the opposite of the Kaizen method. And for a very simple reason: Kaizen advocates continuous change, while Kaikaku literally means "radical change" in Japanese. If it uses it, the company seeks to modify its organization on a specific theme. The upheaval is taking place at all levels of the hierarchy. In general, this tool is often used to improve production processes and team management.
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Kaikaku in addition to Kaizen ?
In reality, these two methods of Lean Management and work are not fundamentally contradictory. In fact, companies often use the Kaikaku method in addition to the Kaizen method. The former allows for great improvements in the short term, while the latter is more projected in the long term. The objective therefore remains the same: to support a significant change in the company and above all to bring quality to the means of production and management, this new production tool makes it possible to drastically reduce quality costs. The latter are indeed absent, which contributes to the optimization of the means of production.
Understanding the 10 Commandments of Kaikaku
When a company uses the Kaikaku method, usually it does not exceed 1 week, or 5 days of actual work. To achieve such an evolution in the space of a few days, the thinkers of Kaikaku have put in place 10 commandments. These make it possible to really grasp the spirit of the method and define a simple action plan.
Forget about traditional manufacturing methods
Focus on what can work, not what might not work
Don't make excuses
Carry out its actions 100% and not make concessions
Do not be excessively perfectionist, any evolution is good to take
Correct errors as soon as they are noticed.
Do not invest money for the application of the method
The opinion of 10 people is better than that of only one
Accept and measure the difficulty
Ask yourself as many questions as possible to grasp all aspects of a change
Explanations
It is noted that the majority of these rules apply to the attitude of the people, rather than to the technical means to be put in place. This is partly what explains Command No. 7: minimization of the financial resources made available for the Kaikaku. The purpose of the approach is to develop a new way of designing and delivering products/services. To do this, however, it is very possible that companies decide to sell their equipment to reinvest this money in, for example, more modern machines. Thus, Kaikaku (in its more traditional form) values individuals, their knowledge and creativity rather than the technological means available..
Un autre aspect important concernant le Kaikaku est la capacité à surmonter des obstacles. Le Kaikaku étant une initiative relativement courte, il faut être en mesure de gérer les difficultés rapidement.
Another important aspect regarding Kaikaku is the ability to overcome obstacles. Since Kaikaku is a relatively short initiative, you need to be able to deal with difficulties quickly.
How to set up Kaikaku?
The organization of such a project is essential, as its consequences can be important.
Before you can actually set up kaikaku, we can identify 3 essential steps:
Elaborate the site, a synthesis of the changes to be made. The consequences, both positive and negative, must be anticipated in advance.
It is then a question of presenting the project to his work team . This is an opportunity for project members to put forward their ideas and get organized.
Use accurate measurement tools to develop forecasts. This step depends on the methods and tools that each company has at its disposal; teams generally prefer the use of Excel or calculation software.
Once these 3 phases have been properly completed, it is possible to move on to the next step: the effective implementation of the project.
Implementation: this involves applying the action plan defined during the preliminary stages.
Verification: this final step validates the adequacy of the forecasts with the results obtained. The objective then becomes to preserve the achievements and improvements obtained over the long term.
At the end of these 5 steps, we can consider the Kaikaku as successful.
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What to plan for before considering a Kaikaku method
As mentioned above, organization and planning are essential to the operation of a Kaikaku method. The difficulties that a team may encounter in this context are often of a human nature.
On the one hand, it is quite common for superiors or management not to see Kaikaku very favourably. It is a method that, quite often, reflects the changes on the entire hierarchical pyramid. On the other hand, it is necessary to ensure the changes that await employees do not rush them too much. Indeed, it is not uncommon for the upheaval of work or its framework to negatively affect employees.
The industrial sector and Lean Management are environments that often make changes of the "Kaikaku" type:
Improved production for Toyota
The Kaikaku method was used by Toyota at one of its Japanese plants to halve its production times, while reducing the production line in question. Example: Toyota used a Kaikaku method at one of its Japanese plants to cut production times in half, while shortening the production line in question. To do this, they were the first to develop injection molding techniques and assembly robots.
The working methods of companies
To ensure that, for example, new software is used in a company, it will first be necessary to install it on all computers (kaikaku) and then train employees in its use (kaizen). This method can easily be applied to several different projects/environments. In general, Kaikaku will be very effective in organizing change processes in companies, especially in organizational terms.
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