Focused Improvement

Kobetsu Kaizen: TPM Pillar for achieving Zero Losses in targeted areas

Focused Improvement—also known as Kobetsu Kaizen is one of the core pillars of TPM that delivers transformative results by eliminating chronic losses and inefficiencies through team-based, data-driven problem-solving.

Kobetsu Kaizen focuses on reducing specific losses in equipment, processes, or operations that impact productivity. The goal is to achieve zero losses in targeted areas such as breakdowns, defects, speed losses, and changeover delays.

Kobetsu Kaizen helps address key losses including set-up and tool change loss, start-up loss, minor stoppages, management losses, operating motion loss, line organization loss, measurement and adjustment loss, tools, jigs, consumables loss and yield loss. By focusing on these targeted areas, Kobetsu Kaizen drives measurable improvements in Overall Equipment Effectiveness (OEE), reduces costs, and fosters a culture of continuous, data-driven improvement.

With our extensive consulting experience in Kobetsu Kaizen (Focused Improvement), we help organizations systematically identify and eliminate the root causes of operational losses. We facilitate structured kaizen events and mentor internal teams through every step – from data gathering to root cause analysis and solution deployment. Our hands-on support ensures that Kobetsu Kaizen becomes a core part of your operational improvement strategy, delivering measurable, sustainable results.

Benefits of Kobetsu Kaizen

Elimination of chronic losses and hidden waste

Rapid gains in productivity, quality, and efficiency

Heightened team collaboration and engagement

Improved morale and ownership at the frontline

Sustained cultural shift toward continuous improvement

Kobetsu Kaizen is the powerful TPM pillar where cross-functional teamwork turns targeted losses into sustainable gains, driving measurable improvements in Overall Equipment Effectiveness (OEE), reducing costs, and building a continuous, data-driven improvement culture.

Key Steps of Kobetsu Kaizen

Identify Major Losses

Conduct OEE analysis to break down performance into availability, performance, and quality losses.
Review historical data and operator feedback to detect recurring issues such as frequent breakdowns, speed losses or long changeover times.
Categorize losses in money value and impact to prioritize high-impact areas.

Form Cross-Functional Teams

Create teams that include representatives from operations, maintenance, engineering, and quality to ensure diverse perspectives.
Define clear roles and responsibilities for each member to promote accountability and ownership

Analyze Root Causes

Use Systematic root cause analysis steps such as Pareto analysis, cause & effect analysis, validation to identify significant causes followed by why why analysis to identify root cause of each significant cause

Develop and Test Solutions

Identify corrective and preventive actions based on root cause analysis
Prioritize solutions based on impact, feasibility, and cost-effectiveness before implementation.
Pilot selected solutions on a small scale, collect data, and evaluate effectiveness before full deployment

Standardize Improvements

Document new procedures and integrate them into updated Standard Operating Procedures (SOPs) and work instructions.
Provide hands-on training and communication sessions to ensure all relevant personnel understand and adopt the changes.
Incorporate changes into audit checklists and daily management routines to reinforce compliance.

Sustain and Share

Establish key performance indicators (KPIs) and dashboards to continuously monitor progress and maintain improvements.
Conduct regular reviews, Gemba walks, and audits to ensure solutions remain effective and are consistently followed.
Share successful practices and learning across other teams, shifts, or production lines to replicate benefits organization-wide.

Our Kobetsu Kaizen Experience & Impact

0 500 +

Focused Improvement Projects implemented

0 + 2000

People trained on Focused Improvement

0 % -50

Reduction in OEE losses

0 % -30

Increase in Manpower Productivity

Key Tools used in implementation of Kobetsu Kaizen

OEE

Root Cause Analysis

SMED

A3 reports

Our Clients Results

Paper Manufacturing

Paper mill boosts OEE and stabilises production through TPM

A structured TPM programme in a paper mill, combined with deep PM analysis, improved Autonomous/Planned Maintenance and standardised shutdown practices, delivered higher OEE, lower downtime and more stable fibre supply to the machines.

Paper Manufacturing

Large Textile & Paper manufacturer strengthens OEE and Cost Performance through TPM Audit

A comprehensive multi-plant TPM assessment across yarn, towel, paper, energy and utilities identified chronic equipment and process losses, created a pillar-wise TPM roadmap, and set clear improvement targets for OEE, downtime, cost and yield across the value chain.

Textiles & Footwear

Textile mill improves moisture regain, yield and equipment reliability in towel packing through TPM

By combining TPM, Autonomous Maintenance and basic environment engineering, the textile mill stabilised packing operations, improved moisture regain and achieved significant yield and cost benefits.

Packaging

Disposable packaging plant cuts energy cost and packing lead time in thermoforming operations

Advanced Lean Manufacturing Tools

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