Kaizen

The concept of work life balance emerged during the Industrial Revolution. In those days Industrialists agreed upon labour union’s demand of ‘One day off’. Later on, this is converted into ‘two day off’ which is followed in all the western countries. Grady et al (2008) stated that the term’ work-life balance’ is more comprehensive and includes “family, community, recreation and personal time.”
The objectives of the research are to study the impact of practices followed in Norway and India on work-life balance, to gain insight on Google company’s work-life balance practices, to identify and suggest vital work-life balance practices that can be applied in Indian context. The research is descriptive in nature. The data has been collected mainly from secondary sources – research papers, annual report of companies (employee engagement) and articles.
The tools used for achieving objectives and analysing are comparison method, case study analysis and survey method. The comparative and case study analysis shows that the education system, job security, income inequality are some of the factors which hinder the work-life balance in India. Flexi hours, time for creativity, family participation in workplace boost the enthusiasm and morale of the employees. The research is based on secondary sources. The primary data would more effectively convey the problems faced in work life balance. The work-life balance practices followed by only one company is taken into the study due to time constraint. The comparative analysis of work-life balance practices of big films would give better insight and would help in deriving dynamic solution. The sector centred, institution centred or gender centred study will give broader overview of the work-life balance. The search acts a base for comparative analysis. Keywords- Work-life balance, stress, employee, family, company.

O objetivo deste estudo e aferir da aplicabilidade da filosofia Kaizen num contexto real, procurando perceber quais as dificuldades subjacentes a implementacao da tecnica dos 5’s e estudar o seu impacto e aceitacao no quotidiano de uma PME portuguesa. Seguindo a metodologia de estudo de caso, do tipo exploratorio, recolheram-se os dados com base na observacao direta e em entrevistas, e procedeu-se a analise qualitativa das respostas. Os resultados obtidos evidenciam uma diminuicao do tempo de movimentacao dos trabalhadores, uma melhoria na qualidade e condicoes de trabalho e um aumento da produtividade. Concluiu-se que a cultura e a comunicacao vertical nao foram fatores impeditivos na implementacao dos principios do kaizen e da tecnica 5’s.

Objectives: Preparation of medical devices from central sterile supply department (CSSD) for use in hospital services requires quality and readiness for use. A guideline for good practice is necessary for safety, assurance, and maximum customer satisfaction, and to accommodate effective healthcare services. We sought to develop and improve medical-device preparation guidelines to satisfy clients. Methods: This action research was based on the concepts of Kaizen and eliminate–combine–rearrange–simplify (ECRS). The research was conducted in 3 phases. In the first phase, we designed the study, conducted problem analysis, and developed a plan for improving the preparation of medical devices. In the second phase, we improved the plan for implementation of medical-device preparation guidelines that the research team adapted and developed. We added inspection categories, trained staff members, conducted a focus group. We improved cleaning processes and the inventory system. In the third ph...

Lean Manufacturing (LM) practices have gained popularity as a means to achieve high-quality products while reducing costs and delivery times. However, the implementation of LM can be challenging, with a high failure rate. This paper aims to explore the perspectives of employees and managers on LM practices implemented in an automotive company. The research involved primary and secondary data analysis, combining observation, interviews, and a questionnaire survey. The survey assessed knowledge and skills, impact on quality improvement, motivation, supervisor support, control, and engagement in LM development. The results highlight the importance of management commitment and support in achieving successful LM implementation. Moreover, the study emphasises the positive impact of LM practices on employee motivation and the overall quality of processes and products. The PDCA cycle emerged as the most impactful tool, along with other recognised tools like Poka Yoke, Andon, Kaizen, Visual ...

O objetivo deste estudo é analisar e propor melhorias no processo de produção de uma indústria fabricante de lubrificantes e desengraxantes, utilizando a ferramenta Lean conhecida como Mapeamento do Fluxo de Valor (MFV). A pesquisa foi conduzida por meio de um estudo de caso, seguindo etapas como formação da equipe, seleção da família de produtos, imersão, mapeamento do MFV atual e desenvolvimento do MFV futuro racionalizado. A abordagem adotada foi tanto qualitativa quanto quantitativa. Os resultados revelaram oportunidades de melhoria, incluindo a consolidação das etapas de inserção de água e mistura de matéria-prima, resultando em uma redução potencial de até 63,50% no tempo/custo (T/C). Além disso, foram sugeridas diversas outras propostas de aprimoramento por meio do plano de ação kaizen 5W1H, sem necessidade de grandes investimentos.

PT. Indofood CBP Sukses Makmur Tbk, DIvisi Food Seasoning adalah perusahaan yang memproduksi kecap, sirup, saos tomat dan sambal, serta bumbu instan. Food Seasoning Semarang selalu berkomitmen untuk mencapai seluruh KPI yang telah ditetapkan oleh manajemen.
Pada awal tahun 2023, manajemen Food Seasoning Semarang menekankan kembali terkait pencapaian output dan penurunan pemborosan di departemen produksi. Bahkan manajemen menetapkan program khusus untuk penurunan pemborosan material khususnya di line produksi dengan tema “Zero Waste”.
Pada line produksi kecap masih terdapat pemborosan pada RM (Raw Material), WIP (Work In Process) dan PM (Packaging Material). Dari data yang ada, pemborosan yang paling tinggi secara amount adalah Pemborosan Work In Process (WIP) pada line packing gallon kecap. Setelah dilakukan analisa lebih dalam, didapatkan akar penyebab masalah adalah (1) Belum adanya integrasi antara timbangan dengan valve, (2) Perbedaan tekanan volume pada tanki gravitasi dan (3) pipa nozzle berukuran panjang. Setelah perbaikan, terjadi penurunan pemborosan dari 2,45% menjadi 0,14%. Untuk segi Cost Efficiency PE dapat turun dari 4.517/ pcs menjadi 4.389/ pcs. Selain itu untuk segi delivery terjadi peningkatan output dari 2.397 pcs/ batch menjadi 2.452 pcs/ jam. Untuk productivity terjadi kenaikan dari 28,41 pcs/ jam/ orang menjadi 34,53 pcs/ jam/ orang. Untuk segi Safety Nilai Index Resiko dapat ditutunkan dari 4 (Medium) menjadi 1 (Low). Serta area kerja pada proses filling menjadi lebih bersih dari ceceran WIP kecap untuk parameter Environment.

Kaizen has long been known as an improvement philosophy that starts with small frequent changes to make larger changes in production. These changes come from the ideas and creative thinking of employees to ensure that the production conditions and processes are continuously improved. However, Kaizen not only helps motivate employees to think creatively with effective methods and skills, but it also helps them develop their capabilities, personality, and good work habits. The purpose of this paper is to show a new approach to human resources quality improvement through the Kaizen philosophy as a sustainable and active strategy to improve work performance. With analytical research on the relationship between Kaizen implementation, human resources quality improvement, and production efficiency and exploratory research on particular cases in manufacturing enterprises in Vietnam, the authors point out changes in production efficiency and human capacity before and after implementing impro...

Vaname shrimp (Litopenaeus vannamei) was kind of shrimp that cultivating by globally. Vaname shrimp has an euryhaline character or able to live on wide salinity. At low salinity watery, the availibility of minerals is too low. This research has to analized using dolomite as pellet for moulting period of vaname shrimp. This research was use sample survey method or field survey, and analyzing descriptively. The value of research shows that adding dolomite at vaname shrimp’s feed could help moulting proccess and growth faster. Growth data in pond 1 shows that MBW is 16,39 g with size 61 and pond 2 MBW is 13,7 g with size 72. Difference result in Mean Body Weight (MBW) is 2,69 g and size difference on 11. Water quality take effect on osmoregulation and metabolic rate. Keywords : Vaname shrimp, dolomite, moulting, growth, water quality

This study assesses kaizen implementation of Asela Malt Factory with respect to 5s, Deming cycle suggestion system, Fishbone Diagram, and Pareto analysis tools. Achievements and challenges encountered in the kaizen implementation are also addressed. Both qualitative and quantitative research methods were employed and SPSS (Scientific Package for Social Science) tool were used to analyze and present quantitative data. Descriptive statistics tools such as frequency and percentage were used to analyze and present qualitative data obtained from questionnaire and interview. The results revealed that kaizen tools are inconsistently implemented in the factory. The study also shows that improvements are achieved in the factory with some variations. On the contrary, numerous challenges are discovered due to the inconsistency of kaizen tools implementation. Therefore, the factory should implement kaizen tools continuously to identify the root causes of the problems, prioritize the problems ac...

In the present work, welding procedures for friction stir welding (FSW) of aluminum alloys were collected from published and unpublished reports, permitting analysis of a diverse collection of alloys, material thickness, tool designs and machine parameters. Spindle torque is a key variable in FSW since it is directly related to heat generation. The compiled data set permitted analysis of spindle torque from a wide variety of welding conditions. To compare heat generation from diverse welding procedures, the torque data and welding tool geometries were used to calculate the average contact shear stress during welding, which was analyzed against the average tool surface velocity for each procedure. The results gave insight into the effects of welding speed, rotational speed and alloy on the average flow stress. The results suggested evidence of reaching a minimum flow stress at high tool surface velocities and a possible effect of initial workpiece temper on conditions during welding.

Economic criteria for assessing the quality costs a company's quality program and corporate stakeholders to pursue their interests in the company seeks to fulfill your expectations and the company expects to achieve anything that customers be it a product, they are. In order to measure the cost of preventative spending quality indicators, quality assessment, failure to break inside and outside and is used to measure the financial performance of the company's operating profit to sales ratio is used. Higher operating profit in addition to providing favorable conditions for companies, banks can increase the credit limit of the company and as a lever to increase the financial strength of the company. The main research question was posed as follows what is the relationship between cost and quality performance of listed companies in the stock market there? Cost includes expenditure in terms of quality has created a challenge for managers and finding the balance point for the compa...

Lean production, pioneered by Toyota, is a methodology aimed at minimizing waste in automotive manufacturing processes. Associated with the Toyota Production System (TPS), Lean production involves implementing various tools to optimize production floor design and operation. This paper provides an in-depth exploration of key Lean tools, including Kaizen, PDCA, Standardization, Jidoka, Poka Yoke, Just in Time (JIT), Heijunka, Kanban, 5S, Andon, and SMED. Kaizen, emphasizing continuous improvement, involves all personnel in systematic small-scale changes to enhance efficiency and quality. PDCA, serving as a framework for continuous improvement, involves planning, execution, evaluation, and adjustment. Standardization establishes best practices, ensuring consistency across procedures. Jidoka focuses on quality control, halting processes upon detecting defects. Poka Yoke, or mistake-proofing, prevents errors through mechanical design. JIT aims to produce only what is needed when it is needed, minimizing waste. Heijunka regulates production flow to achieve smooth operation. Kanban facilitates demand-driven production through visual scheduling.5S promotes workplace organization and cleanliness. SMED minimizes setup time for efficient product changeovers. The paper offers detailed insights into each tool's implementation and significance in Lean production, emphasizing their role in waste reduction and process optimization.

Aim of Study: The aim of the study was to assess how quality cycles impact the performance of tea processing companies in Kenya. The research was guided by Deming's quality improvement theory. Pragmatism research philosophy was employed in this research. Study Design: Further, explanatory research design was deemed appropriate for the research. Methodology: The study population under consideration was 66 operations managers of all the tea producing companies. A census of all the 66 operations managers was conducted. Utilizing structured questionnaires, both quantitative and qualitative data was gathered for analysis. Data analysis was undertaken utilizing SPSS Version 23.0. Results: The findings revealed that quality cycles had positive and significant relationship with performance of tea processing firms in Kenya where (β =.335) and p=.011). The study concludes that quality cycles are critically important in the production of tea. Tea processing firms need to cultivate culture ...

PurposeThe purpose of this paper is to present a capability maturity model (CMM) developed to implement continuous improvement in small and medium scale construction companies (SMSCC) in Nigeria.Design/methodology/approachA multi-strategy approach involving qualitative studies of SMSCC in Nigeria was conducted. Semi-structured interviews were conducted with purposively selected construction experts in Nigeria to identify variables essential for continuous improvement in SMSCC. Data collected were thematically analysed using NVIVO. Subsequently, a system thinking approach is employed to design and develop the CMM for implementing continuous improvement SMSCC, by exploring possible relationships between the variables established.FindingsCMM provided a five-level approach for the inclusion of investigated variables such as team performance; culture; structure; post-project reviews, financial risk management, waste management policy and cost control. These variables are factors leading ...

Japan is one of the most ethnically homogeneous countries in the world. Although there is an indigenous minority Ainu ethnic group from Hokkaido Prefecture and indigeneous inhabitants of the Riukiu (Okinawa) archipelago, the Japanese communally share the core values that form the core of their sense of cultural and national identity. Hall and Hofstede's concepts provide a reference point for the present reflections on specific aspects of the Japanese cultural code, encompassing the sociological and psychological concepts of uchi-soto, honne-tatemae, and wa. Awareness of the role the Japanese attribute to social harmony helps sensitise the unique communicative culture of the Japanese and, under certain circumstances, to break down cultural barriers. Internalising this attitude can help a non-Japanese demonstrate proper social etiquette and maintain communicative harmony. My own experience of experiencing cultural difference in Japan from the perspective of a woman, a European, and a Polish researcher, provided a direct impetus to analyse the underlying cultural concepts that underlie Japanese communicative culture, as well as the perception of the dichotomy of Self versus the Other.

Excelencia en base a calidad es prioritario en la empresa moderna. La filosofía Kaizen, aplicada por la Toyota, es el caso de éxito mundial más emblemático y demuestra que con esta metodología es posible elevar los estándares de productividad en las empresas. En Latinoamérica y sobre todo en el Perú, aún estas técnicas son poco conocidas. El objetivo de esta investigación fue divulgar la efectividad de la estrategia base para el Kaizen: la metodología de las 5S.  Partiendo de la premisa Kaizen “que todo cuanto existe se puede mejorar”, las 5S son fundamentales en los procesos de mejora continua representando una alternativa en las empresas, para lograr efectos considerablemente positivos; sin embargo, por muy fácil y de bajo costo que parezca su implementación, esta demanda de mucho compromiso, desde la alta gerencia hasta el empleado del último orden jerárquico de la empresa.

A forma como sao tratados os dados esta a mudar radicalmente a gestao e os processos organizacionais. A quantidade de informacao disponivel atualmente e inumera e continua a crescer, as maquinas produzem mais informacao util que o ser humano, e podemos vivenciar isso atraves do fenomeno Big Data. O objetivo deste artigo, por um lado, e abordar o conceito de Big Data nas varias areas da sociedade e o que este implica na auditoria financeira analisando as varias vantagens e desafios apresentados por diversos autores e profissionais. Por outro lado, atraves de estudo empirico baseado em inquerito e entrevistas, e tratar a necessidade que a profissao apresenta de utilizar Big Data nos procedimentos de auditoria e as principais barreiras apontadas pelos auditores. Tambem se pretende estabelecer bases para impulsionar pesquisas futuras, pois e um tema muito pouco tratado em Portugal, e com uma dimensao significativa no mercado. O estudo empirico permitiu concluir que Big Data e fundamenta...

Abstract. PT. X is a company that produces plastic sacks, where the company has two plants located in Bandung. The first plant or the Production Department carries out the activity of processing plastic pellets up to sack rolls, while the second plant or the Finishing Department carries out the activity of cutting sack rolls to sack packing lots. However, this research was conducted in the Finishing Department. After conducting observations and interviews, in the Finishing Department there are several activities that lead to waste including defective products, waiting time, transportation, and inventory. The identification of the type of waste is done by filling out the EDOWNTIME form through the production supervisor and describing the Value Stream Mapping (VSM), from VSM it can be seen that the Total Lead Time (TLT) is 8,065.17 seconds with a Process Cycle Efficiency (PCE) value of 69.34%. The waiting time affects the length of the TLT. In addition, the average sigma value can als...

Este estudio explora el impacto de Kaizen, una filosofía japonesa centrada en la mejora continua, en diversas organizaciones de distintos sectores. Kaizen promueve pequeños cambios incrementales para mejorar la productividad, eficiencia, calidad y reducción de desperdicios. A través de un enfoque de métodos mixtos, se analizaron datos de empresas en los sectores de manufactura, servicios y tecnología, ubicadas en Japón, India y Estados Unidos.

Los resultados muestran un aumento significativo en los indicadores clave de desempeño (KPI) tras la implementación de Kaizen. La productividad mejoró en un 25%, la eficiencia operativa (OEE) aumentó un 15%, las tasas de defectos se redujeron en un 30% y la reducción de desperdicios promedió un 20%. El éxito de Kaizen dependió en gran medida de la participación activa de los empleados en todos los niveles de la organización. Sin embargo, surgieron desafíos en empresas fuera de Japón debido a diferencias culturales y resistencia al cambio, lo que subraya la necesidad de adaptar Kaizen a contextos locales.

Los hallazgos destacan el potencial de Kaizen como una herramienta poderosa para fomentar una cultura de mejora continua. Aunque desarrollado originalmente en Japón, Kaizen puede ofrecer beneficios significativos en todo el mundo, siempre que su implementación se ajuste a los contextos culturales y operativos específicos de cada organización.

Palabras clave: Kaizen, mejora continua, productividad, eficiencia, calidad, reducción de desperdicios, cultura organizacional, eficiencia operativa.

Continuous improvement projects (CIPs), such as Kaizen events, Six Sigma projects, Lean Six Sigma projects, and quality improvement projects, have been used to improve processes and system performance in organizations. Although CIPs have a determinant role in continuous improvement initiatives, research concerning the use of CIPs in hospitals is relatively new. Therefore, the purpose of this paper is to identify the main research topics addressed, including research methods and analysis tools used, in scholarly works on CIPs in hospitals. A systematic literature review was conducted, which identified 302 academic publications (journals, conference proceedings, and dissertations/theses). The research design characteristics were evaluated using bibliometric analysis identifying a high concentration of publications focused on describing CIP implementations, using case studies as research methods, and applying several problem-solving tools. These findings suggest that CIPs in hospitals ...

BFM is a pharmaceutical company that produces bulk Tetanus Toxoid (TT). Bulk TT demand will continue to increase until 2025, while the current utilization rate has reached 97% of its design capacity. Bulk TT's current production capacity is insufficient, while the building area cannot be enlarged. This research was conducted to improve non-necessary value added by identifying and reducing waste to run well even though the production capacity is limited. Mix descriptive qualitative and quantitative methods are applied in this research. Production simulation is undertaken to reduce waste through the Gemba Kaizen approach and Kanban, while production capacity simulation is carried out using Dynamic Systems. The results of the simulations are described in the Balanced Scorecard. The research revealed there are 148 wastes consisting of 4 causes of waste in the high priority category, 20 medium priority and 124 low priority. The simulation generates a significant decrease value of the...

This study aims to determine and explain: the description of the role of leadership styles at University of Sumatera Utara through motivating the application of Kaizen culture to employee performance. The type of research used in this research is an explanatory research using quantitative methods. The variables in this study are: leadership style and improvement culture as independent variables, work motivation as the mediating variable, and employee performance as the dependent variable. This research uses primary data in the form of responses to the questionnaire, as well as secondary data obtained through documents. The data analysis method used is path analysis. The results of path analysis show that: leadership style variables have a positive and significant impact on employee performance, Leadership style variables have a positive and significant impact on motivation, Kaizen cultural variables have a positive and significant impact on employee performance, Kaizen cultural vari...