Kaizen event approach: a case study in the packaging industry

Brian Vo · Elif A. Kongar · Manuel F. Suárez‐Barraza

46 citations0/0 files storedInternational Journal of Productivity and Performance Management

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Quality and Supply Management Management and Optimization Techniques Management Systems and Quality Improvement

Abstract

Purpose The purpose of this paper is twofold: first, a case study on the application of lean production principles in a manufacturing facility is presented to demonstrate the impact of frequent and systematic use of a Kaizen event on quality and delivery performance. Second, the detailed description and analysis of the Kaizen event and its impact are provided, including a comprehensive analysis of the role of Kaizen events on employee participation and motivation. Design/methodology/approach The study utilizes a Kaizen event’s case study data with the help of various waste detection and elimination tools and techniques. Changes in overall productivity along with potential long-term improvements in the delivery process are also analyzed and documented. Findings Pre- and post-quality measures are provided to demonstrate the results of the event on the production quality and on the performance of the overall manufacturing processes. Qualitative findings regarding performance measurements and the impact on the employees are reported. Research limitations/implications The Kaizen team applied analytical techniques to one manufacturing site in North America of a company that has a manufacturing presence in 20 different countries. Originality/value Kaizen studies involving packaging operations are quite limited. This study fills this gap by detailing the Kaizen event implementation in a packaging delivery and dispensing systems manufacturer for the cosmetic industry. The implementation of this Kaizen event is detailed along with the data and techniques utilized for process improvement. The study also reports findings regarding the impact of the Kaizen event on employee participation.

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References

2007Theory Building From Cases: Opportunities And Challenges 2002Case research in operations management 1995Explaining Development and Change in Organizations 1968Managerial Attitudes and Performance.1997What is a processual analysis?1981Assessing Measurement Error in Key Informant Reports: A Methodological Note on Organizational Analysis in Marketing 1974Measuring the Job Satisfaction of Industrial Salesmen 2007Engaging the aging workforce: The relationship between perceived age similarity, satisfaction with coworkers, and employee engagement.

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2024Achieving social sustainability through lean manufacturing practices: Insights from structural equation model and system dynamics 2021Kaizen event process quality: towards a phase-based understanding of high-quality group problem-solving 2020Deploying Kaizen events in the manufacturing industry: an investigation into managerial factors 2022Green quality circle: Achieving sustainable manufacturing with low investment

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