Disadvantages Of Kaizen Costing
Kaizen is a Japanese word that has become common in many western companies. It is a compound word involving two concepts: Kai (change) and Zen (for the better) (Singh & Singh, 2009:51). Kaizen costing is the application of continuous improvement principles to reduce costs in the manufacturing stage of a product’s life. Successful kaizen programs can do more than reduce costs; they also increase the quality of products and the safety of production processes. (Cooper & Slagmulder, 2005b:271). It operates in feed-forward mode by setting cost-reduction objectives in anticipation of the need to reduce costs rather than reacting to cost overruns after they occur. It complements TC by extending the discipline that TC creates in the product development process to the manufacturing stage. (Cooper & Slagmulder, 1999:271) Figure 4-5: The Decision to Move Activities among Firms in SC
Adopted from Cooper & Slagmulder (2005a)
One of the great differences between TC and kaizen costing is that in TC if cost reduction opportunities are lost, they are lost until the next generation of the product is introduced. In contrast, under kaizen costing they can be recaptured the following year by setting more aggressive cost-reduction objectives.
According to Shang & Sui Pheng (2013), there are two types of kaizen that require daily activity. The first is maintenance kaizen, which mainly deals with unexpected matters or inevitable mistakes that occur at the workplace, such as breakdowns, changes,
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