Lean-Kaizen implementation

Abstract

Purpose The purpose of this paper is to present a road map to implement Lean-Kaizen concept using value stream mapping (VSM) to identify hidden continuous improvement opportunities in a small and medium-sized enterprise (SME) located at the non-capital region of India. Design/methodology/approach From the collected data, a current state map was prepared that indicated the current operating situation of selected SME. The takt time was calculated and those processes which attained higher cycle time (C/T) than takt time were identified. The continuous flow processing was achieved by adjusting C/T of each process and supermarket pull system was developed to control the production at the workstations. Finally, a future state map was developed that served as a guide for future lean activities. Few problems were identified to realize the future state. The “5-why” analysis was used for identifying root causes of these problems and Kaizen events were proposed as solutions. In this case study, one Kaizen event was identified in which brainstorming technique was used to control the variation caused by unorthodox fixture design for clamping and de-clamping of case product and thus eliminated non-value-added activities performed by the operator on a milling machine. Findings Before and after implementation of value stream map, the data obtained were analyzed and eliminated rework time, reduced inventory level, reduced lead time and C/T, improved productivity and product quality are presented as finding. Lean-Kaizen provides a better chance for every individual of the industry to have a hand in achieving organization’s goals to attain continuous progress in productivity and quality of the product. Even good understanding of the concept of lean tools and techniques by SMEs, the employee willingness and motivation to identify and eliminate wastes are found feeble. Originality/value This study is among best practices to identify hidden improvement opportunities in the regular production of the product to increase productivity and improve quality using value stream map. The research paper gives useful understandings to the lean implementers, Kaizen identifiers, consultants and researchers.

Evaluating the Five Kaizen Success Measurements Through Employees Work Improvement and Its Effects on Overall Work and Quality of Services: Empirical Study of Insurance Companies in Jordan

“…The study of Kumar et al (2018). The study aimed at presenting road map for the implementation of Lean-Kaizen method using value stream mapping (VSM) to search for unknown continuous improvement opportunities in a small and medium-sized enterprise (SME) located at small cities in India.…”

Introduction to Lean Waste and Lean Tools

“…For Kaizen implementation no initial cost is required or with in very less money it can be give big profits. Neither it cannot change the floor layout, nor it is need any advanced technology [17,18,40,42].…”

Modelo de Gestión de mantenimiento basado en Lean Manufacturing para incrementar la productividad de una empresa del sector de Plástico

“…• Implementar 5S: Ya habiendo sentado las bases del conocimiento y alertar de la importancia de este paso, es importante hacerlo paulatinamente con la aceptación de los trabajadores, un cambio brusco solo ocasionaría una resistencia al cambio y que la sostenibilidad del modelo falle. [13].…”