Question 1

What is the difference between Kaizen and Six Sigma?

Accepted Answer

Kaizen focuses on continuous, incremental improvements involving all employees, while Six Sigma is a more structured methodology that uses statistical tools to reduce defects to a very low level (3.4 per million opportunities). Both aim to improve quality and efficiency, but Kaizen is often simpler and more accessible for small-scale changes.

Question 2

How do I identify the seven wastes in a process?

Accepted Answer

Start by observing the process from the customer's perspective. Look for activities that do not add value. Common examples: defects (rework), overproduction (making more than needed), waiting (idle time), non-utilised talent (not using staff skills), transportation (unnecessary movement of goods), inventory (excess stock), motion (unnecessary movement of people), and extra processing (doing more than required). Use a value stream map to visualise these wastes.

Question 3

What is the purpose of the 5S methodology?

Accepted Answer

The purpose of 5S is to create a clean, organised, and efficient workplace. It reduces waste from searching for tools, improves safety by eliminating hazards, and increases productivity. Each 'S' builds on the previous: Sort (remove unnecessary items), Set in Order (organise remaining items), Shine (clean the workspace), Standardise (create consistent procedures), and Sustain (maintain the system through discipline).

Question 4

Can business improvement techniques be applied outside manufacturing?

Accepted Answer

Yes, absolutely. Techniques like PDCA, 5S, and waste reduction are used in healthcare, IT, education, and service industries. For example, a hospital might use 5S to organise medical supplies, or a software team might use PDCA to improve their development process. The principles are universal for any process that can be measured and improved.

Question 5

How does the PDCA cycle work in practice?

Accepted Answer

Plan: Identify a problem and develop a hypothesis for improvement. Do: Implement the change on a small scale. Check: Measure the results and compare to the expected outcome. Act: If successful, standardise the change; if not, revise the plan and repeat the cycle. For example, a factory might use PDCA to reduce setup time by testing a new tool organisation method.

Question 6

What is the role of employees in continuous improvement?

Accepted Answer

Employees are the key drivers of continuous improvement. They are closest to the processes and often have the best ideas for improvements. In a Kaizen culture, all employees are encouraged to suggest changes, participate in improvement events, and take ownership of their work area. Management supports by providing time, resources, and recognition.

iCQ Level 2 Award in Introduction to Business Improvement Techniques (RQF)

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