Robots, smart factories, the latest in 3D printing–cutting-edge technology like these always makes headlines, but sometimes the best solutions are simpler, as proven by karakuri kaizen. The karakuri kaizen framework might have been created back in the 1950s, but it’s still a powerful system that many of the top manufacturing companies today implement.
This guide will walk you through the essential principles of karakuri kaizen and how to put them into action. By the end, you’ll already be getting ideas about how to implement it in your organization, no matter the size or industry.
How does karakuri kaizen work?
Karakuri kaizen is a lean manufacturing concept that comes from Japan, and its focus is on making simple, low-tech mechanical solutions to improve processes, without having to use electricity. Instead, these rely on basic physics principles, such as gravity, springs, gears, pulleys, and counterweights. For example, a delicate wooden puppet could spring to life with graceful movements just by pulling a cord.
Unlike robotics or sophisticated machines, karakuri kaizen emphasizes minimalism. Instead of using an electric conveyor belt to move objects around, a karakuri kaizen solution might be to use inclined planes and gravity to get the same result. This consumes a lot less energy, reduces complexity and also lowers maintenance costs. Because of this simplicity, it’s also pretty quick to implement, and it even encourages workers and engineers to be creative and rely on available resources.
As you can tell from the name, karakuri kaizen is part of the broader kaizen philosophy, which is all about continuous improvement. The Kaizen philosophy advocates small changes that build on each other, which in the long run should produce holistic improvement. It is a continuous process instead of one-time corrective actions. Similarly, with karakuri kaizen, the mechanical solutions aren’t set in stone–they evolve. Teams are always looking for ways to refine the mechanisms, whether by reducing parts or finding even better designs.
Key elements of karakuri kaizen
Let’s dive deeper into karakuri kaizen by looking at its key principles:
- Simplicity: One of the core ideas of karakuri kaizen is keeping things simple. Solutions should be straightforward, easy to understand, and intuitive to use. Ideally, you’d use resources that are already available.
- Sustainability: Karakuri kaizen aims to cut down energy usage by using mechanical systems instead of electric or hydraulic systems. Since these systems just rely on natural forces like gravity, there’s almost no energy consumed. This aligns well with lean manufacturing, which aims to reduce waste.
- Creativity: Just because karakuri kaizen encourages simple systems doesn’t mean that there’s no room for creativity. In fact, workers and engineers end up thinking more outside the box, coming up with innovative solutions for challenges that they might face day to day.
- Cost efficiency: This is another pillar of karakuri kaizen. The idea is to come up with solutions with little to no extra cost, with no need to make huge investments in new machines or technology. It can be a great strategy for companies that are looking to cut costs but still want to be efficient.
- Maintenance: Once karakuri kaizen systems have been set up, they’re also cheaper and easier to maintain. There are fewer moving parts, they’re less dependent on external power, and there are essentially fewer things that can go wrong. If something does break, fixing it is less intimidating because of the minimalistic design.
Examples of karakuri kaizen in action
Karakuri kaizen is used the most often in manufacturing, especially in lean production settings. Toyota, a leader in lean manufacturing, actually adopted karakuri kaizen because it was “inspired by the craft behind the mechanical puppets.” They’ve even optimized their production lines based on it, with the goal of carbon-free manufacturing.
Here are some fascinating examples of karakuri kaizen in action:
Manual lifting systems
Instead of electric or hydraulic lifts, karakuri kaizen uses systems like counterweights or pulleys to lift and move heavy objects. With these setups, workers can move items with minimal effort, while also still not using powered equipment. By leveraging basic principles, you can actually balance loads effectively and make the tasks easier and safer.
Mechanical triggers
Mechanical triggers involve setting off a chain reaction using simple physical actions. When you push a lever or press a button, gears start turning, parts are moving, and everything clicks into place. These systems rely on clever mechanical linkages instead of complex electronics, so they’re much easier to repair.
Automated Doors or Hatches
In many manufacturing setups, you might have doors or hatches that open on their own automatically–not because of motors, but because of old-school mechanics like springs and counterweights. These kinds of doors are perfect in factories because they cut down on energy use and don’t need a lot of attention to keep running smoothly.
How to implement karakuri kaizen
Since it’s part of the broader kaizen philosophy, karakuri kaizen also follows the PDCA cycle:
1. Plan
During the planning stage, the main focus is on developing a solution. First, identify the problem and evaluate the causes. Finally, problems based on the analysis can be precisely addressed through defined and planned goals. In the planning phase, the greatest attention to detail is required to see success later on.
2. Do
In the second phase, the aim is to extensively test if the solution worked out in the first step. By testing, the occurrence of undesirable side effects can be ruled out. Now the actual implementation must be coordinated step by step. Ideally, the tasks should be delegated to a team of experts. Furthermore, the process and the results should be well documented.
3. Check
This is about the evaluation of the Kaizen method. Are the solutions to the problems reasonable and efficient? If the defined solutions and goals are achieved, the method can be extended to other areas in a targeted and consistent manner.
4. Act
When the desired goal(s) have been achieved, a standard for quality assurance should be implemented in the respective processes. If the desired result was not achieved, further corrective measures must be specified and the cyclic principle must be carried out again.
Best practices for karakuri kaizen
Here are some best practices to keep in mind as you implement karakuri kaizen.
First, use existing resources–in other words, work with what you have. Instead of investing in expensive new technologies, karakuri kaizen challenges you to think creatively about how to use basic, sometimes overlooked resources in new ways. Whether it’s using scrap metal or turning old conveyor parts into gravity-fed systems, you can save money and take action faster by making the most out of what’s on hand.
Loop employees in on the problem-solving process. After all, the best ideas often come from those who are closest to the work, and there’s a lot to gain from learning about others’ hands-on experiences and practical knowledge, especially shop-floor workers. They interact with the machines and processes all the time, so they’re in a good position to identify inefficiencies and brainstorm possible solutions.
Test and iterate. Testing is crucial in karakuri kaizen–once a solution is designed, it will then be tested rigorously to make sure it works as planned. The PDCA (Plan, Do, Check, Act) cycle is a perfect framework for this. By constantly refining prototypes through repeated testing, each new version of the solution is better than the last.
Record and share successful implementations. After all that work, you have got to celebrate the successes too and pass them on. When a solution works well, it should be documented in detail and shared across teams. Aside from leaving behind a good record, it might also inspire other people to think creatively and contribute their own ideas, creating a ripple effect across your organization.
Of course, solutions should be easy to maintain. Karakuri kaizen systems should also be easy to adjust, repair, or upgrade without needing highly specialized skills or tools. Another benefit of this is that workers can make small fixes themselves, which keeps processes running much more smoothly.
Other methods associated with karakuri kaizen
Aside from kaizen itself, karakuri kaizen is compatible with a lot of other methods. Here are some of the most popular ones:
5S (6s Lean)
The 5S methodology is used for the efficient design of the workplace. The aim is to achieve a minimalist, resource-saving workflow. The extension of this practice is 6s Lean. In addition to an efficiency-determined work process, safety at the workplace is also controlled and optimized.
Just-in-time (JIT) manufacturing
JIT manufacturing focuses on reducing inventory costs by producing only what is needed, when it is needed. Usually, companies would produce large batches of products and store them in inventory, hoping to meet future demand. But with JIT, waste is reduced because components and products are only manufactured once customer orders are received.
Poka-yoke
This is another lean method with a preventive approach–it aims to design systems so that errors are unlikely to occur. In fact, the goal is to make it impossible or at least very difficult for workers to make mistakes. Maybe sensors won’t allow a process to start if a step is missed, or there might be warnings or alerts if workers are about to make an error.
The ultimate digital tool for karakuri kaizen success
Digital checklists allow you to easily implement and monitor continuous improvement efforts. The digital app guides you step by step through your checks or audits. You can document, analyze, and check work steps anytime and anywhere.
With automatic report generation, you always stay up to date with the latest developments and share them with the right people. Use the checklists as a useful kaizen tool, which can be flexibly adapted to your company’s needs, and start a new, more transparent, and efficient corporate communication today. Also benefit from the following advantages:
- Generate real-time data about internal processes. This makes quality and safety measurable, and you can use data to constantly optimise processes.
- In addition, we offer more than 10,000 ready-made templates to help companies get started digitally in no time.
- Using the super intuitive mobile app, you and your teammates can conduct checks in the field with ease.
- All results, images, and comments are automatically bundled in a digital report.