Abstract
There is strong evidence that Zambian manufacturing organisations are increasingly implementing Kaizen programs to help them improve productivity and enhance delivery performance. This study aims to investigate the relationship between Kaizen practices and improvement in performance in Zambian manufacturing companies. The study also sought to determine the challenges faced by manufacturing companies in implementing Kaizen practices. The study employed a cross-sectional descriptive research design with the target population being manufacturing companies in two highly industrialised regions in Zambia. Thirty-three questionnaires were distributed, and 31 companies responded. Based on the conceptual framework developed, hypotheses were formulated and tested using the ordinary least squares regression modelling approach. The results show that the 5Ss were the most popular activities implemented, while the Suggestion System was the least implemented. Implementing Kaizen practices leads to significant operations performance improvements in manufacturing companies in the form of productivity, quality, and overall equipment effectiveness. The results also show that employee attitude is the major challenge in implementing Kaizen, while management support or leadership is the last hurdle. The research provides an early understanding of the successes of the implementation of Kaizen practices in manufacturing companies in Zambia.
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