10 case studies for kaizen implementation
TRANSCRIPT
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1KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Leading Textile Equipment Manufacturer
Performance Indicator
Benefit Realized
Quantum of Improvement
Overall inventory Reduced 55%
Order to delivery time Reduced 50%
Manpower productivity Increased 58%
Break-Even Point Reduced 30%
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2KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Pharmaceutical I
Industry Details Performance Indicator
Benefit Realized
Quantum of Improvement
Tablets Yield Enhanced By 2.1% to reach 99.6%
Lyophilization Capacity Increased Without Investment
80%
Vaccine Packing Line Productivity Increased 30%
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3KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Pharmaceutical II
Industry Details Performance Indicator
Benefit Realized
Quantum of Improvement
Vial Packing Manpower Productivity Increased 32%
PFS Packing Manpower Productivity Increased 92%
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4KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Stainless Steel Tube Manufacturer
Performance Indicator
Benefit Realized
Quantum of Improvement
OEE(Overall Equipment Efficiency)
Improved From 46% to 66%
Capacity Increased without Investment 44%
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5KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Plastic Thermoware Manufacturers
Performance Indicator
Benefit Realized
Quantum of Improvement
Assembly Productivity Went up 250%!!
Floor space in assembly Reduced 60%
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6KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Garment Industry
Performance Indicator
Benefit Realized
Quantum of Improvement
Manpower Productivity Went up 90%
Space used Reduced by 30%
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7KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Precision Automotive & Aerospace Components Manufacturer
Performance Indicator
Benefit Realized
Quantum of Improvement
Manpower productivity Went up 25%
Space required Reduced by 17%
Manufacturing Costs Went down 31%
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8KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Aircraft Electricals EOU
Performance Indicator
Benefit Realized
Quantum of Improvement
Throughput time (& Inventory) Reduced 48%
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9KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Rubber Products
Performance Indicator
Benefit Realized
Quantum of Improvement
Manpower Productivity Went up 38%
Material Wastage Reduced 37%
Order to Delivery time Went down 67%
Market Share Went up From 34% to 48%
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10KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Automotive Ancillary
Performance Indicator
Benefit Realized
Quantum of Improvement
Total Inventory Reduced 60%
Manpower Productivity Went Up 100%+
Space used Reduced by 55%
Rejections Went down 80%
Delivery Performance Went up From 65% to 100%