Kaizen Approach Research Articles

Kaizen as a Form of Lean Management to Improve Human Performance in the Organization

This research aims to identify one of the important improvement approaches currently in the business world, namely Kaizen, which has achieved the enhancement of the quality of the organization's outputs and the achievement of the success it aspires to, which has been reflected in achieving profit and excellence, and effectively in improving the performance of human resources in particular, as we will learn about the mechanism of this, by reviewing the most important aspects related to the concept of the Kaizen approach, passing through to give a general picture of its impact on human resources performance, and reaching to shed light on the Japanese experience in managing human resources using the Kaizen approach. The study concluded that it is necessary to follow the Japanese experience in managing human resources, given its effective role in improving performance and keeping pace with the contemporary changes and challenges witnessed by the business environment.

Improvement of the Resuscitation Environment with the Modified Toyota Kaizen Approach Via In Situ Anaesthesia Simulation Training.

Improvement of the Resuscitation Environment with the Modified Toyota Kaizen Approach Via In Situ Anaesthesia Simulation Training.

The combination of the kaizen approach with the Design of Experiment (DoE) method for improving quality of the bread and donut products in SMEs

Competition for Small and Medium Enterprise (SME) products is currently getting tougher, in terms of quality, timely delivery, and competitive prices. SME customers of bread and donut products sometimes complain about the visual quality of bread and donut products that are stale, burnt, and dirty. The purpose of this research is to reduce product defects during the production process and improve the quality of the bread and donut products. This research method uses a Kaizen approach combined with the Design of Experiment (DoE) one-shoot case study method and uses organoleptic tests to assess the quality of bread and donut products. This study found that there were 3 product defect problems, namely bread and donut defects that did not rise, burnt donut defects, bread defects, and dirty donuts. This research resulted in a decrease in defects of 65% from 3.84% to 1.07%. While the best DoE test results used dough type C with 10 grams fermipan/yeast composition and 15 grams bread improver, stove 165-1750C, equipment cleaning frequency 1 time for each dough, and organoleptic test with 10% beetroot extract addition resulted in a color aspect score of 70 %, 65% aroma aspect, 68.5% texture aspect, and 70% taste aspect which is liked by many people.

Application of Kaizen Principles to a Small Scale Industry in India

This case-study presents the application of Kaizen concept to Chempromech Engineers Pvt. Ltd. in Butribori, Maharashtra, India. The work carried out focuses on Kaizen approach to the Plant Layout of the industry to make it more efficient and desirable to work in as well as gives a formula to the industry to calculate its production in kg/hr theoretically. Chempromech Engineers Pvt. Ltd. Is a small scale industry present in the Butibori MIDC area in Nagpur, Maharashtra which specializes in manufacturing of circlip washer wires and washers. Being a small-scale industry, it is faced with problems pertaining to limited workspace, so a new layout is designed which helps groups machines based in their product type and thus freeing out space for future expansion. Product Based Plant Layout is preferred for this industry as its products vary in size and weight. Key words:- Kaizen, Plant Layout, Product Based Plant Layout, Washers and Washer wire.

A PROPOSAL FOR APPLYING THE KAIZEN METHOD IN YOUTH AND PROFESSIONAL SPORTS

The purpose of this study is to examine the prevalence and applicability of the Kaizen approach in sports. Because it is a widespread phenomenon with great social and cultural significance, sport is prone to highly dynamic, discontinuous, non-linear, and uncertain changes. Major changes (kawar)[1] that affect sport as a social and economically important activity in today’s unstable environment pose risks to both the management and the player. The idea behind using the Kaizen approach in sports and the sports industry is to encourage individual participation and continual improvement through a clear and detailed procedure that is tailored to the genuine requirements of every professional athlete. Globalization and socio-technological advancements have had a significant impact on sports and sports activities, and success is now solely determined by monetary value. The Kaizen method can improve the efficiency of every individual, every athlete, and even sports organizations. As a team, the management of the sports organization can accomplish the goals set before itself more quickly with the application of the appropriate Kaizen method, with the quality setting of the operational and logistics management, with gradual and continuous improvement of the makeup and organization of its operations. It is acknowledged that spreading the Kaizen method outside of its country of origin is a powerful tool that aims at the rationalization and effective utilization of all available resources. The goal of the Kaizen technique is constant improvement, which eliminates all unrealistic factors that influence how sports values, such as results, are achieved.
 
 
 
 

A solution approach proposal with a lean perspective for the poultry sector with WRM and BWM integration

PurposeThis study aims to analyze lean wastes for the poultry sector in Turkey and link lean tools to this study, focusing on identifying each lean waste that affects poultry production and proposing solutions for preventing these lean wastes in the sector. The proposed solutions aim to improve processes by suggesting different lean tools and their applications for the poultry sector.Design/methodology/approachThe study consists of two different applications. First, the waste relationship matrix (WRM) was created to reveal the relationship between seven lean wastes and their importance order. Then, after determining lean tools for eliminating lean wastes, the optimum weight ranking and consistency ratio of the most suitable lean tools were calculated for these wastes and ranked with the best-worst method (BWM).FindingsResults showed that overproduction is the most critical waste that impacts other wastes, followed by defect waste. Due to the nature of the sector, these wastes not only result in economic loss for the company but also in food waste and loss and issues related to animal welfare. Furthermore, the Kaizen approach and 5S implementation are the methods to eliminate these wastes. Detailed discussion on the link between lean tools and lean wastes is provided for the poultry sector.Originality/valueThis is the first study that theoretically and empirically identifies the potential lean waste affecting the poultry sector and provides lean tools for eliminating these wastes. Sector-specific explanations and discussions are presented in the study to show the applicability of lean approaches in the poultry sector to eliminate waste. In addition, this study is the first to integrate the WRM and BWM.

A-174 More Timely Patient Care Amidst Healthcare Staffing Shortages, Reducing Blood Specimen Tube Barcode Errors for Continuous Flow in an Automated Laboratory System

Abstract Background The Core Laboratory at Henry Ford Hospital utilizes total laboratory automation to support chemistry, hematology and coagulation analyzers, processing approximately 10 000 specimens daily. Testing and reporting delays can occur when the system encounters a specimen tube barcode error. Specimens will stop moving and causes approximately a 2-minute per error production pause while the error is resolved. This induces congestion for all other specimens in line behind the error. The seemingly trivial minutes of congestion leads to a domino effect, resulting in reduced line productivity, a temporary limit of testing capacity and prolonged TATs. The laboratory receives specimen tubes with labels generated from over 600 printers. The system encounters 200–250 errors daily associated with barcode read failures of various types. Errors account for an estimated loss of ∼320 h of staff productivity per month. Methods Automation line error files, manually recorded data from lab staff, observations of automation line errors occurring in real time, data from a printer maintenance blitz and barcode printer service requests were used in root cause analysis. Three progressive Kaizens events were organized in 2022 to induce rapid process change through focused chartering of events and actions. A probing study designed to induce controlled defects and stoppages helped recognize where congestion on the line was occurring. Simulation of barcode application errors allowed an understanding of the impact of label application. Staff and line productivity loss analysis predicted the potential opportunity of error reduction. Results Fifty-five percent of the barcode errors were caused by improper label application and 45% were poor print quality of the barcode on the label. Of the label application defects, 55% were caused by the label being placed upside-down, of which 34% were caused by the label format used by our Emergency Department. Print quality issues such as faded or pitted printing labels accounted for 45% of errors. The printer preventive maintenance blitz successfully reduced print quality errors by 30%. Converting to a more robust printer in two high-volume areas resulted in zero print quality errors over three months. Barcode label format changes were 100% effective in eliminating upside-down as a root cause. Conclusion Elimination of barcode line errors can recover 2.0 FTEs in three divisions per month, while increasing automation line productivity and a cost approximately$150 000 per year in work delays and unnecessary rework. The Kaizen approach to problem-solving allowed for rapid brainstorming amongst multiple teams. Altered label format allowed built-in engineering control by mistake-proofing the process and making label positioning irrelevant. Identification of areas where high volumes of labels were being printed and replacing those printers with more robust printers reduced service calls and eliminated printer causal factors since these printers require less hands-on maintenance. Finally, instituting preventative label printer maintenance and total quality management reduces or prevents errors associated with print quality. Sustaining mechanisms include continued real-time data documentation and communication of defects, collaboration with colleagues in Nursing for further root cause analysis of barcode application defects.

Increasing Energy Efficiency Based on the Kaizen Approach

The energy crisis, an increasing concern of the industrial sector, is characterized by increased energy costs and low energy availability. As part of an effort to increase energy efficiency, the present study assessed the impact of applying lean tools on the energy consumption of a manufacturing organization. Using the Kaizen approach, the organization’s processes were analyzed to identify the main vulnerabilities and make the required changes to increase consumption performance. Several technical improvements were performed to reach increased energy efficiency. Results showed an energy efficiency increase; consumption was reduced by up to 7.5% in the production line, 3.5% in the extruder stage, and up to 20% for the injection stage of the manufacturing process. The results suggest that the organization’s energy reduction targets have been achieved. Standardization of procedures was useful in the development of Kaizen projects which could be applied with certain limitations. The implications of these results for understanding energy consumption reduction are discussed.

Implementation of Lean Manufacturing to Reduce Hold Types of Mission Case Products using DMAIC and KAIZEN Approach

Company in this research is a manufacturing company engaged in the automotive industry that produces transmissions for four-wheeled vehicles. This research was conducted at the ALMC department which specializes in producing Mission Cases. In carrying out this Mission Case production activity, it is still found that there are Hold defects or pending parts because the quality does not meet the requirements to be flowed in the assembly process. The types of defects are kizu (berets), dakon (dented due to impact) and atsukon (dented due to scrap.) As a result, the company has to incur additional costs to repair the part (overprocess)so that it can be transferred to the assembly process. The purpose of this research is to minimize the Hold defects by implementing lean manufacturing through DMAIC and KAIZEN approaches. The identification of waste in the production line is carried out using value stream mapping tools and the Hold defect problem analysis stage is solved using DMAIC tools. The results of this study are expected to minimize smallpox hold with the implementation of lean manufacturing

Balanced Scorecard with KAIZEN approach for Increasing SMEs Performance:

Balanced Scorecard with KAIZEN approach for Increasing SMEs Performance:

Kaizen Approach to Quality Improvement and its Financial Implication

Purpose: This study aims to investigate the impact of kaizen practice and how it affects the quality of large manufacturing firms particularly, Kilimanjaro international leather company.
 Design/methodology/approach. In this study, the Plan-Do-Check-Act (PDCA) cycle technique was employed to lower the production process's defect rate. The fishbone served as a tool for support. The PDCA cycle and fishbone are two top-notch techniques that aid in reducing the number of defective parts.
 Findings: The defect rate decreased by 2%. Improvement in the production process was achieved.
 Research limitation: One large manufacturing industry is insufficient to generalize the study's primary results. This will be achieved in the future by doing additional investigations in several large manufacturing firms.
 Practical implication: This study will provide consultants and practitioners with a valuable understanding of how Kaizen improves the financial performance of large manufacturing industries in Tanzania.
 Social Implications: The majority of learning exercises carried out during kaizen projects seek to enhance social outcomes in terms of staff members' problem-solving skills and attitudes. Particularly, Kaizen coordinators are concerned with group members' understanding of continuous improvement as well as their communication and problem-solving abilities.
 Originality/Value: Although some studies on kaizen have been conducted, it is currently discovered that there is insufficient literature on the application and impact of the kaizen concept in large manufacturing enterprises. Based on this case study, the framework of kaizen philosophy practices is offering useful insights for leather companies, other manufacturing industries, and organizations, including the Tanzania Kaizen unit, practitioners, and academicians.

The impact of Kaizen approach on neurodevelopmental follow-up of high-risk infants

ABSTRACT Kaizen methodology was implied as a tool for analyzing the current workflow, defining opportunities, developing a solution, and measuring the outcome. The current study aims to verify the early effect of a quality improvement study within the scope of the Kaizen approach to improve the quality of high-risk infant care. Initially, a value stream map was used to define the current follow-up plan. Then, a specific outpatient clinic was established with a standard follow-up schedule. The high-risk infants were evaluated with the same tools at the same corrected ages, and the multidisciplinary team performed appropriate family education. The early outcome was evaluated by Parents’ Satisfaction Levels with High-Risk Infant Care Questionnaire and Parenting Stress Index-Short Form. Thirty-four parents were included. The mean corrected age of the infants was 140.07 ± 146.55 days. Parents’ satisfaction scores were improved from 99.79 ± 17.17–121.61 ± 15.33 (P = 0.000), while perceived stress scores were decreased (98.03 ± 23.55 vs 86.18 ± 20.95), (P = 0.001). The main stages of the quality improvement process were described. The current research presents the preliminary results of a Kaizen implementation for neurodevelopmental follow-up of high-risk infants.

Redesign Facility Layout with a Kaizen Approach in Testing Laboratory at Balai Pengujian & Sertifikat Mutu Barang Makassar

In trading activities, especially exports in the food commodities sector, several documents must be made and completed by exporters, such as Certificate of Quality, Test-Certificate, and Chemical Analysis. Balai Pengujian & Sertifikasi Mutu Barang Makassar is a government agency operating in South Celebes that tests the quality of various agricultural and plantation commodities. From year to year, demand for testing services has increased along with the number of exports. So, testing activities have changed in terms of facility layout requirements resulting in overwhelmed in carrying out the testing process. Test rooms are not connected based on the current testing flow causing the tester’s ineffective work patterns. This study aims to redesign the layout of the facilities in the testing laboratory with the Kaizen approach to support the smooth testing process. The results of this study indicate that the proposed floor area uses a 150% allowance so the calculation requires a floor area of 42.52 m2 . After that, an analysis of the proximity of the facilities is carried out by making ARC (Activity Relationship Chart) and ARD (Activity Relationship Diagram). Based on ARD, a template is made for the layout of testing laboratory facilities. This study applies Kaizen theory with the 5S concept to obtain a neater design, namely Seiri and Seiton in the refreshment laboratory and weighing room, Seiso on testing equipment in all testing laboratory rooms, Seiketsu and Shitsuke applied to all rooms in the testing laboratory.

A Practical Guide to the Kaizen Approach as a Quality Improvement Tool.

A Practical Guide to the Kaizen Approach as a Quality Improvement Tool.

Integrating Seven Tools and Kaizen Approach in Evaluating Defects on Tofu Production Process

UKM Tofu ADA is a tofu producer that makes an effort to develop the quality standardization of the tofu production process. Managing tofu quality through maintaining the production process is challenging, resulting in no good tofu. Defective products cause economic loss and the inability to fulfill customer orders. This study aims to evaluate defects in the tofu production process using the Seven Tools and Kaizen approach. The results of this study configure three types of product defects. Namely, mushy, cracked, and crushed. The highest percentage of defects is mushy tofu, with 43.8%. The proposed improvement using kaizen analysis is the Kaizen Five-M Checklist.

Kaizen Method Implementation in Industries: Literature Review and Research Issues

A business philosophy in a corporate organization that involves all elements from the leadership level to workers to contribute to the processes that support an organizational system, such as work and time efficiency, work environment and safety, waste management, production processes and other processes. Kaizen has been widely accepted by various types of industries, both manufacturing and services, in response to these requirements, because kaizen itself can eliminate waste without additional resource requirements. This research aims to know and provide information about Kaizen implementation from various types of industries. This paper uses the literature review method of research papers that generally apply kaizen. A total of 52 research papers have been reviewed as research contributions, type of research methodology adopted, techniques and tools used, type of industry, and year of publication. The results obtained were published in many researchs about kaizen at 2012-2019, Kaizen approach can solve kind of problems such as quality, consumption energy, lead time, performance problem, etc. to improve the work system, widely applied in various industries such as: manufacturing, logistics, construction, SME, service, healthcare, pharmaceutical and processes for continuous improvement.

Analysis of Lean Process Factors to Improve Production Process Effectiveness (Case Study in BFM Pharmaceutical Industry)

BFM is a pharmaceutical company that produces bulk Tetanus Toxoid (TT). Bulk TT demand will continue to increase until 2025, while the current utilization rate has reached 97% of its design capacity. Bulk TT's current production capacity is insufficient, while the building area cannot be enlarged. This research was conducted to improve non-necessary value added by identifying and reducing waste to run well even though the production capacity is limited. Mix descriptive qualitative and quantitative methods are applied in this research. Production simulation is undertaken to reduce waste through the Gemba Kaizen approach and Kanban, while production capacity simulation is carried out using Dynamic Systems. The results of the simulations are described in the Balanced Scorecard. The research revealed there are 148 wastes consisting of 4 causes of waste in the high priority category, 20 medium priority and 124 low priority. The simulation generates a significant decrease value of the waste priority number (WPN) from 347.3 to 47.2. There was also an increase in the overall value stream. Value-added ratio (VAR) increased 12.57%, production lead time reduced 21.01%, and total cycle time decreased 11.65%. These findings indicated that the improvement was effective in eliminating waste. From the overall improvement, there was an increase in productivity of 25.0%.

Kai and Zen: Effective Tools for Improving Productivity and Quality: A Case Study of an Indian MSME

Old manufacturing methods have become obsolete and are ineffective in the current era of highly competitive global markets. The customer expectations have seen a dramatic shift in tastes and preferences due to large product availability that keeps on improving with time. Nowadays companies are forced to adopt new manufacturing methods that facilitate growth, notably lean manufacturing tools, and related techniques have seen a positive acceptance worldwide. Furthermore, kaizen is one of the effective tools that are based on the principle of the right use of workers’ potential and capabilities. The present case study is done in an industry engaged in manufacturing child parts which are used in gearbox assembly, transmission, hydraulic lift assembly, etc. for original equipment manufacturers. Henceforth, these issues formed the basis for the current study. Furthermore, a road map was developed that was based on understanding the current manufacturing process, thorough analysis of records, followed by detailed employee interviews. Moreover, this study used a kaizen approach that involved people from the shop floor that lead to many positive suggestions and practical implementation. Finally, this study successfully improved overall product quality and met customer expectations without any major financial investments. The positive findings of this case study saw tangible gains in the form of Withdrawl Nut P252006 additional rework cost reduced from 5.82% to 0.41% and in-house rejection (scrap) cost reduced from 0.84% to 0.03%. Pre Loading Nut P124034 additional rework cost reduced from 5.97% to 0.34% and in-house rejection (scrap) cost from 0.89% to 0.02%.

University leadership styles using the Kaizen approach

The current research seeks to enhance current university leadership styles by using the Kaizen approach from a university leadership point of view it also highlights the requirements needed to improve university leadership by applying the Kaizen approach. To achieve these objectives, the research uses the questionnaire as a tool to collect research data and applies this to the leaders, faculty, and staff of four universities in the MENA area. The research sample consists of 160 individuals (including deans, co-deans, department heads, faculty, staff, and employees) from four different universities. The research concluded with several results, from which the majority of the sample first agreed that there is a lack of a Kaizen approach culture among university leadership, and also agreed on the importance of applying Kaizen principles as a model for enhancing university leadership.

ОЦІНКА ЯКОСТІ БІЗНЕС-ПРОЦЕСІВ ПІДПРИЄМСТВА

The article discusses approaches to assessing the quality of business processes of a shoe manufacturing enterprise. To assess the quality of business processes, first of all, business processes are identified. Marketing activity, supply of basic and auxiliary materials, technological preparation, production, sales of finished products, personnel management, financial management, environmental management, information and digital management were chosen as key processes at the shoe manufacturing enterprise by a group of experts. The quality indicators of each business process are determined, which can be classified according to the following groups: indicators of functional suitability, costs, time, efficiency and effectiveness, impact on the environment, flexibility. The system of the above indicators is called a business process panel. The following methods are used to determine the value of business process quality indicators: organoleptic, measurement, registration, calculation, sociological, expert, statistical, etc. The direction of optimization is determined using logical thinking. Normalization of indicators is carried out – the transformation of all dimensional indicators into dimensionless quality indicators (desirability functions), which range from 0 (very poor quality) to 1 (very good). At the same time, the desirability scale of E. Harrington is used. Unit, сomplex and integral indicators of the quality of business processes of the enterprise are calculated according to the proposed formulas. The final stages of assessing the quality of business processes are the analysis of the obtained results and their improvement. In the practical activity of enterprises, two approaches to improving business processes are distinguished: breakthrough, fast, radical improvement, which is called reengineering, and small permanent improvements in small steps, changes for the better – kaizen. The Kaizen approach has the following frameworks, the use of which is appropriate in a shoe company: lean manufacturing, six sigma, lean manufacturing plus six sigma, kanban, Scram technologies, TRM and the 5S system.