Kaizen case study

Creating pool of multitasking workers.

benefits of kaizen pdf

Everyone was able to put forward their views and all appropriate ideas for improvement were considered. Then we measure how long all the individual components took to deliver and what the error rate was.

Use of quality programmes like JIT and Kanban. Simulation and evaluation To confirm the possibility of implementing the alternative method, simulation was undertaken. Leyland therefore encourages everyone to be involved in decision making. For example, there is always a risk that rival manufacturers, e.

Providing the alternative methods Following Kaizen steps, team developed seven technical ideas to improve storage of the rods.

Case study on kaizen implementation pdf

The major product of the company is front axle and rear axle. Minimization of cost and increase in productivity is achieved because operators become efficient. Lack of multiskilled workers. How Kaizen works A good example of how Kaizen is implemented at Leyland relates to the introduction of a robotic paint spray booth for the truck chassis. Inefficient coordination Objective. Someone who assembles part of the truck suspension will have a reasonably good idea about how the processes they work on could be improved. It currently supplies its products to Tata Motors Jamshedpur and Lucknow plants for commercial vehicles. Streamlining the. Each day we reviewed the failures from the previous day and improved the process. We identified what needed to be done and gave people specific roles within the process. What kind of products are manufactured, how much time is consumed in the process, what kind of waste processes are generated are all taken into account. Cost effectiveness Information System Changes Brought. Relevant task were given to carry out at relevant work stations.

An average of customers called this office every day. Brainstorming session Designing new storage methods.

Kaizen case study

It was clear what steps had to be completed but they were all seen in isolation of each other. One of the suggestions was to continue with the current method but that was not a waste eliminating process. Inefficient coordination Objective. It was to help operators to locate personnels easily. It was explained at regular meetings and posters were placed all around. Simulation and evaluation To confirm the possibility of implementing the alternative method, simulation was undertaken. Multiskilled employees. To view more companies, please choose a letter from the list below. We made something over changes to their core processes in five months. Weakness in Product. Increasing the efficiency. As a result food was often delivered cold and late.

No one knew what the process was. Daily average dropped from Oftent we made 20 — 30 small changes a day. In contrast a prompt answer after just two rings reassured them and made them feel more comfortable.

We made something over changes to their core processes in five months.

Kaizen case study ppt

Each day we reviewed the failures from the previous day and improved the process. Leyland is not able to raise prices because of competition, so any increase in wages has to be compensated for by more efficient production to protect jobs in the UK. Evaluate and select best solution The best method was an alternative number two where three rods are extruded from the pull-truder. These included marking the floor and work areas with tape, moving tables, redesigning job roles, kanban boards, anything in fact that was perceived to offer and improvement. It comes from the words 'kai' continuous and 'zen' good or for the better. They were growing rapidly and as a result had started to have lots of problems. Cause and effect diagram.
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Kaizen : Techniques and Case studies