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ABSTRACT
Thousands of small & medium scale industries are present in India. All are facing certain problems resulting in shortage of production and quality issues like productivity, greater lead time, processing time etc. The paper contains basis definition of kaizen philosophy & a brief review of kaizen concept & its implementation. The purpose of this paper is to represent Kaizen, its related terms in a concrete way & its implementation in improving the overall effectiveness of organization. This paper illustrates about kaizen implementation in small manufacturing industry & also focuses on the scenario of Indian manufacturing company while implementing Kaizen. The paper also illustrates the implementation of kaizen technique in a company who is dealing with manufacturing the PVC pipes. The company is currently facing with the problem of increased lead time and backorders. The main objective is to implement kaizen practice in the case company. This implementation is focused on reducing the lead time of sales order processing by mean of which the productivity of organization will be improved. We also suppose to generate case based simulation models which estimate the basic Kaizen implementation process before & after implementation. The tools used are Kaizen, 5S, kaizen sheet 5S sheet etc., and monte-carlo simulation method (for analysis).
Keywords: Productivity improvement, quality management, KAIZEN, 5S principles
Kaizen is Japanese philosophy which means continuous improvement. 'Kai' mean Change & 'Zen' mean "Good" the whole purpose of which is betterment of work & improving the organization efficiency. The concept of Kaizen is so deeply ingrained in the minds of Japanese people that they often do not even realize that they are thinking Kaizen. Japanese people uses the inborn instinct of being continuous change present in every human being & work for betterment by using existing resources available within the firm instead of spending lot much money on technologies. The kaizen implementation crucially includes the complete involvement of employees from worker to top level of management in the organization. Kaizen involve small but continuous improvement & this small change can improve the productivity in huge multiplication .in short Kaizen distinguish as the best method of performance improvement among all the techniques as it involve less implementation cost.
Nowadays, organizations carry on seeking innovative ideas for improving their processes...