The term Karakuri or Karakuri Kaizen is derived from the Japanese word meaning a machine or mechanical device used to assist a process with limited (or no) automated resources. Its origins come from the mechanical dolls in Japan that essentially helped lay the foundations of robotics.
Karakuri is one of the many tools associated with the Lean concept and methodology. Using the basics of its concepts allows us to dive deeper into business process improvement, but from a cost reduction perspective. This will ultimately allow us to find innovative solutions with a smaller budget. This is why Karakuri Kaizen is commonly used in Lean Manufacturing.
The main benefits of implementing Karakuri include:
• Cost Reduction
Karakuri Kaizen allows for significant cost reductions in a variety of ways. By reducing production cycle times and lowering overall automation and material costs as processes are optimized, operations will be able to reinvest in themselves more, as their bottom line will be positively impacted.
• Process Improvement
In synergy with other Lean concepts, Karakuri reduces overall cycle time by “automating” processes with devices, rather than relying on manual motion. As in the Toyota example, breaking down a process and finding non-value-added steps will help determine which elements will benefit from Karakuri’s innovative solutions and structure.
• Quality Improvement
Process improvement has a direct impact on product improvement. Inefficient production processes increase the likelihood of defects and potential errors, so planning the most efficient processes and routing can only further improve product quality.
• Simplicity of Maintenance
Automated systems lead to increased maintenance costs, especially for operations that rely almost entirely on automation. This will typically result in the need for a 24/7 maintenance team if the system fails, which it often will. Karakuri devices are easy to maintain due to their simplicity and the materials they are made from, so managers don’t have to spend a lot of money on new departments and teams to keep things running smoothly.
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Post time: Sep-26-2024
