Strategic Implementation of the PDCA and 5S Concepts to Improve the Productivity of the Informal Welding Industry in Kumasi, Ghana

Abstract

The informal welding industry is one of the major SMEs in Ghana. The industry is however confronted with a lot of challenges which, therefore, can be addressed by the use of Plan-do-check-act (PDCA) and 5S concepts. This study evaluated the benefits of the PDCA and 5S concepts as strategic tools for improving the performance of the informal welding industry in Kumasi, Ghana, by using the exploratory research technique. The PDCA and 5S concepts were implemented for a period of six months using 50 welder industries selected by the stratified random sampling procedure. The diagnosis of the current state of the industry was initially measured through performance indicators generated through questionnaires, interviews and direct observations. The design of the solution strategy was then implemented using the concepts to mitigate the challenges previously identified. This was followed by data collection to monitor the performance of the study factors. The results showed a significant (66%) general improvement in the cleanliness of the work environment, work safety and health of workers of all the study workshops. There was also a general decrease in defective products, and reduction in raw material waste and an enhanced aesthetic value of products. A total of over 17 productivity variables were evaluated out of which 11 saw between 4% and 96 % improvement, which in all translated into boosting the morale of workers and customer confidence. The study contributes to the paradigm shift of SMEs to modern management systems for enhanced performance and competitiveness. Keywords: Continuous Improvement, Ghana, Informal Welding, Operational Excellence, Plan-Do-Check-Act (PDCA), Strategic Implementation