Quantitative analysis of Kaizen philosophy on productivity improvement

Abstract

Due to rising global competition and major changes in consumer demands, preferences, and tastes, many businesses today use the Japanese management technique known as Kaizen to adjust their production processes to meet these expectations. The sole goal of this study was to improve the overall productivity of medium-scale industries by integrating the kaizen philosophy into the production process. Most learning exercises carried out as part of kaizen initiatives were designed to improve social outcomes regarding employees’ problem-solving skills and attitudes. In particular, Kaizen coordinators are concerned with employees’ understanding of continuous improvement and their communication and problem-solving abilities. The pilot project was carried out in the production lines where vanilla extracts were being produced. The Plan-Do-Check-Act (PDCA) cycle technique was used in this study to improve productivity in the production process. The pitch diagram was used as a supportive tool. The two prominent techniques that mainly contributed to the increase in productivity were the PDCA cycle and the pitch diagram. Kaizen implementation led to a 37% increase in the company's total productivity. To increase productivity even further, water tapping and measurement were merged. As a result, it took just 2 minutes instead of 5 to fill a bottle with 20 liters of water. This study concludes that the Kaizen philosophy and elimination of non-value-adding tasks from the production process improve output.