Kaizen is a philosophy of Japanese origin that literally means “change for the better”. In the industrial context, it is a systematic approach to continuous improvement, involving all employees — from the operator to the engineer — to eliminate waste, improve processes, and enhance quality.
In the industrial testing environment, Kaizen allows for the reduction of cycle time, elimination of recurring failures, and making the process more robust, traceable, and efficient.
🧠 The fundamental principles of Kaizen
- Small daily improvements are more effective than sporadic drastic changes
- Involvement of everyone: operators, technicians, engineers, and leaders
- Identification of root causes (5 Whys, Ishikawa)
- Focus on the process, not just the results
- Mindset of experimentation and constant learning
🧩 Examples of Kaizen application in testing and automation
- Standardization of test scripts and operational interfaces
- Reduction of setup time between different products (SMED applied to software)
- Improvement in the ergonomics of test benches and jigs
- Elimination of redundant steps or unnecessary measurements
- Automation of repetitive or manual tasks
- Implementation of visual alerts for critical failures or process deviations
- Use of dashboards to identify bottlenecks and improvement opportunities
🔧 How AJOLLY Testing supports Kaizen in its projects
AJOLLY Testing applies Kaizen as an integral part of the development and implementation process of testing and automation solutions, focusing on efficiency, reliability, and continuous improvement.
🔍 Identification of opportunities
- Analysis of failure reports (Pareto, FPY, cycle time, OEE)
- Technical audit of test stations focusing on added value
- Involvement of production and quality teams in improvement suggestions
🛠️ Technical implementation of improvements
- Quick updates of software, sequences, and test logic
- Redesign of jigs or replacement with faster and more reliable modules
- Integration of sensors, timers, cameras, or additional automations
📊 Measurement and traceability of improvements
- Comparison of indicators before and after the Kaizen action
- Automatic generation of impact reports (time saved, reduced failure rate)
- Digital recording of implemented Kaizen actions and their history
With AJOLLY Testing, Kaizen is not just a philosophy, but a constant cycle of technical, collaborative, and measurable evolution applied to the real world of industrial testing.