“What gets measured, gets managed”. ~Peter Drucker
There is no kaizen without standards, and we cannot establish standards without measurements.
Standards are required to efficiently manage the work areas on a daily basis. Every time problems arise, managers should go to gemba to revise the existing standards, investigate what happened and identify the root cause for the non-conformance. Sometimes, the problem is that there is no standard. To be able to understand the problem and later on create standards we need to collect data of the current status and analyze it. Why happened? When? How? As soon as you answer these questions, establish a temporary countermeasure on the spot and then find the root cause. If the real cause of the problem is not identified, it will happen again. After the root cause identification standardizes to prevent a recurrence.
The three major kaizen activities are standardization, 5S and elimination of Muda (waste). All three requires gathering some kind of data and analyze it to get improvements. A lack of 5S can be considered a sign of inefficiency. A good 5S program, on the other hand, is very helpful to identify right away non-conformance situations and facilitate the starting point to start the investigation process.
Good measurements are critical for kaizen, they provide a picture of the current process. Metrics need to be aligned with the company KPI’s and easy to understand by the production floor employees. The metrics selection, their accuracy, and precision are very important to the success of the continuous improvement activities. Wrong or inaccurate metrics will lead us to take wrong decisions.