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%.