Impacts of Kaizen in a small-scale industry of India: a case study

2014 ◽  
Vol 5 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Amit Kumar Arya ◽  
Sanjiv Kumar Jain
Keyword(s):  
Poor Quality ◽  
Value Stream Mapping ◽  
Small Scale ◽  
Content Type ◽  
Value Stream ◽  
Small Scale Industry ◽  
Production Techniques ◽  
Small Industries ◽  
Small Scale Industries

Purpose – A large number of small-scale industries have shown their existence in India, tough competition among them made the survival of small industries difficult. All facing problems like reduced production and poor quality. The case study presented in the paper deals with Kaizen implementation in a machine vice manufacturer company. Kaizen has tremendous impacts on the production techniques and lead times. Case study represented is to motivate practitioners for implementing Kaizen in small-scale industries of India. The paper aims to discuss these issues. Design/methodology/approach – The methodology applied to implement the Kaizen in Indian small-scale industry. Fishbone diagrams have been used to represent cause and effects. The result has been shown as savings in terms of money and time. Findings – Processing time has been reduced by 44.4 percent and an amount of Rs. 64,000 has been saved by recovering a total of 80 square feet working area. Improvements in the form of work flow have been achieved. Research limitations/implications – Value stream mapping can be integrated with Kaizen for more reduction in the product lead time. Practical implications – The paper will be worthily for practitioners and consultants for understanding Kaizen implementation in small-scale industry of India. Originality/value – The paper yields lots of values for practitioners to understand the impacts and significance of the Kaizen in small-scale industries of India. Also it bridges the gap between theory and practical of Kaizen implementation in small-scale industry of India.

Assessing the application of Kaizen principles in Indian small-scale industry

2015 ◽  
Vol 6 (4) ◽  
pp. 369-396 ◽  
Author(s):  
Amit Kumar Arya ◽  
Suraj Choudhary
Keyword(s):  
Poor Quality ◽  
Theory And Practice ◽  
Access Time ◽  
Small Scale ◽  
Content Type ◽  
Small Scale Industry ◽  
Production Techniques ◽  
Small Industries ◽  
Indian Industries ◽  
Small Scale Industries

Purpose – This study aims to represent Kaizen implementation in a machine vice manufacturing company. Kaizen has shown tremendous impacts on the production techniques and lead times. A large number of small-scale industries have shown their existence in India. It has been difficult for small industries to survive due to tough competition among them. All are facing problems like low production and poor-quality products. Design/methodology/approach – The methodology applied to implement Kaizen in Indian small-scale industry. Fishbone diagrams have been used to represent cause and effects. The result has been shown as savings in terms of money and time. Findings – Inventory access time is reduced up to 87 per cent and total distance travelled and total time taken by product is reduced up to 43.75 and 46.08 per cent, respectively. A habit to maintain a clean workplace has been developed in workers. Research limitations/implications – ISO could be integrated with Kaizen for more improvements. Practical implications – The paper should assist those practitioners and consultants who have the desire to understand a better way of Kaizen implementation in small-scale industries of India. Originality/value – This paper yields lots of values for practitioners to understand the need, impacts and significance of Kaizen implementation in small-scale industries of India. Also, it bridges the gap between theory and practice of Kaizen implementation in real working conditions in Indian industries.

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

2019 ◽  
Vol 11 (3) ◽  
pp. 493-514 ◽  
Author(s):  
Aatish Kumar Mishra ◽  
Ayush Sharma ◽  
Moraldeepsingh Sachdeo ◽  
Jayakrishna K.
Keyword(s):  
Manufacturing Industry ◽  
Main Tool ◽  
Organizational Level ◽  
Value Stream Mapping ◽  
Simulation Approach ◽  
Content Type ◽  
Study Approach ◽  
Value Stream ◽  
Sustainable Value

Purpose The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach. Design/methodology/approach The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation. Findings Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process. Research limitations/implications The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level. Practical implications It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts. Originality/value The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.

scholarly journals Influence of Input Value and Labor Expenditure on Output Value: A Case of Micro and Small Scale Industry in Indonesia

2020 ◽  
Vol 4 (1) ◽  
pp. 45
Author(s):  
Tongam Sihol Nababan ◽  
Elvis Fresly Purba ◽  
Jongkers Tampubolon
Keyword(s):  
Production Function ◽  
Analytical Method ◽  
Production Functions ◽  
Small Scale ◽  
Small Scale Industry ◽  
Labor Expenditure ◽  
Production Output ◽  
Small Industries ◽  
Small Scale Industries ◽  
Descriptive Method

Objectives of the study are: (1) to estimate the influence of input value and labor expenditure on the output of micro and small industries in Indonesia, (2) to analyze the form of translog production function that is compatible with micro and small industries in Indonesia. The analytical method used is descriptive method and analysis of translog production functions with scenarios: linear translog function, complete second-order or quadratic linear translog function, and linear translog function with interaction. Results showed that (1) the function of linear translog production with interaction was more suitable used to estimate the production output of micro and small industries in Indonesia, (2) input value and labor expenditure had a positive and significant effect on output values, (3) micro-industry enterprises more emphasis on the allocation of larger workforce, while small-scale industry emphasizes greater allocation of input value, (4) the allocation of input value and labor expenditure are more efficient in micro-industries compared to small-scale industries.

Lean manufacturing implementation using value stream mapping as a tool

2014 ◽  
Vol 5 (1) ◽  
pp. 89-116 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Aditya Sharma
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Process Time ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Work In Process ◽  
Current State

Purpose – Value stream mapping (VSM) is a lean manufacturing (LM) tool used for analyzing material and information flow on a specific product family. The purpose of this article is to address the importance of VSM in LM environment in an Indian auto components industry. Design/methodology/approach – The case study approach has been used to show the applicability and importance of VSM in an Indian auto components company, in which the current state of manufacturing is mapped with the help of VSM symbols. According to the current state mapping, the study conducted analysis and identifies the area of improvement needed in terms of work in process, lead time and cycle time. The study further implemented kaizen on the current state map and developed future state map while including these kaizens. Findings – The study clearly shows that the VSM brings out the positive impact on process ratio, TAKT time, process inventory level, line speed, total lead and process time and reduced man power. It is helping the company in satisfying their customers with respect to quality, cost and delivery. Research limitations/implications – The main limitation of the study is the confined focus on a single industry. The case should be extended to other industries in order to support the findings and for the purpose of the wider generalization. Practical implications – The results obtained from the study will help other industries and sectors to implement VSM in LM environment. Originality/value – The article deals with a real case study, which shows application of VSM for implementing lean principles.

An Optimized Model for Reduction of Cycle Time Using Value Stream Mapping in a Small Scale Industry

2016 ◽  
Vol 27 ◽  
pp. 179-189 ◽  
Author(s):  
R. Suganthini Rekha ◽  
P. Periyasamy ◽  
S. Nallusamy
Keyword(s):  
Cycle Time ◽  
Flexible Manufacturing ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Small Scale ◽  
Value Stream ◽  
Small Scale Industry ◽  
Manufacturing Applications

In recent times, lean manufacturing applications have become essential for manufacturers all over the globe. The manufacturers have gradually shifted from mass production to flexible manufacturing and customers are looking for customized and unique products. Productivity becomes a very important element with multiple product need. Passenger vehicle seat manufacturing industry is found to be poorly affected by manufacturing problems due to more cycle time, unbalanced workload and improper layout. The main aim of this paper is to study the existing system of a seat manufacturing industry and to improve productivity using lean methodology without much affecting current working systems. The critical non value added activities are identified and chances required for improvement has been recognized. The total lead time was reduced from 2.55 days to 2.438 days after implementation of applications of VSM. Using spaghetti diagram the current layout was optimized and the total cycle time was reduced by about 26.28% after implementing the proposed layout to meet the customer demand.

An application of value stream mapping in auto-ancillary industry: a case study

2019 ◽  
Vol 32 (1) ◽  
pp. 162-182 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Srinivas Kota ◽  
Kuldip Singh Sangwan
Keyword(s):  
Product Family ◽  
Value Stream Mapping ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Auto Component

Purpose Lean manufacturing (LM) plays a major role in eliminating wastes (activities/resources) in a manufacturing organization. Value stream mapping (VSM) is one of the critical tools in LM which will help in identifying wastes in materials and information flow in a specific product family. The purpose of this paper is to illustrate the significance of VSM in the auto-ancillary industry in enhancing the productivity and the quality. Design/methodology/approach A case study approach is followed to demonstrate the significance of VSM in identifying various wastes in the auto-ancillary industry. The study has been performed by implementing seven critical steps. A product family is identified based on the customer demand and a cross functional team with specialized experts was formed. The overall processes with sequence are mapped using process flowchart. A cross functional team has been formed to develop the current state of VSM and perform a critical analysis to identify shortcomings. An investigation was performed to overcome the existing shortcomings by identifying opportunities. The relevant kaizens to improve the current state have been proposed. The cross functional team of experts have performed a feasibility study on implementation of proposed kaizens. Finally, a future state of VSM after implementation of feasible kaizens has been reported. Findings The results show that future state of VSM brings out the positive impact with respect to process ratio, TAKT time, process inventory level, total lead time and bottleneck time. The proposed improvement also helped to achieve higher customer satisfaction in terms of increased quality, reduced cost and on time delivery. Research limitations/implications Present study is focussed on a single product family cell in one of the auto-component organization. Originality/value Helps practitioners in the auto-component industry to implement the VSM effectively in their organization.

Cost value stream mapping as a lean assessment tool in a small-scale industry

2020 ◽  
Vol 30 (1) ◽  
pp. 72
Author(s):  
B. Rajesh Menon ◽  
P.R. Shalij ◽  
K.R. Kiron ◽  
J. Sreejith ◽  
P. Sajeesh
Keyword(s):  
Assessment Tool ◽  
Value Stream Mapping ◽  
Small Scale ◽  
Value Stream ◽  
Small Scale Industry ◽  
Lean Assessment

Lean service system design: a simulation-based VSM case study

2019 ◽  
Vol 25 (7) ◽  
pp. 1802-1821 ◽  
Author(s):  
Fatih Cavdur ◽  
Betul Yagmahan ◽  
Ece Oguzcan ◽  
Nazli Arslan ◽  
Nurbanu Sahan
Keyword(s):  
Design Methodology ◽  
Simulation Models ◽  
Public University ◽  
Decision Makers ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Simulation Based

Purpose The purpose of this paper is to present a methodology for using simulation models together with value stream mapping (VSM) for designing lean service systems and illustrate it with a case study. Design/methodology/approach The authors propose a methodology combining simulation and VSM. Simulation models for both current and future states are developed to validate the results of the corresponding maps of current and future states, respectively. Findings The results illustrate the advantages of the suggested design represented by the future state map. Additionally, using simulation models together with VSM for validating current and future states also allows decision makers to perform comprehensive analyses on the system and draw statistical conclusions. Originality/value Although some lean applications in educational services exist in previous studies, according to the best of the authors’ knowledge, this study is the first one combining VSM and simulation for the implementation of the lean concepts in the construction and technical services of a public university.

Supply chain value stream mapping: a new tool of operation management

2016 ◽  
Vol 33 (4) ◽  
pp. 518-534 ◽  
Author(s):  
Manuel F. Suarez-Barraza ◽  
José-Á Miguel-Davila ◽  
C. Fabiola Vasquez-García
Keyword(s):  
Supply Chain ◽  
Quality Management ◽  
Supply Chains ◽  
Case Studies ◽  
Operation Management ◽  
Value Stream Mapping ◽  
Business World ◽  
Content Type ◽  
Value Stream

Purpose – The issue of the supply chain has been given much attention in recent decades, both in the academic arena as well as in the business world. It has become so important that organizations have begun to directly manage the supply chain, appointing specific managers to perform this function. New challenges now include a focus on supply to determine the right time and place for product delivery. Some authors indicate a close relationship between Total Quality Management and the supply chain regarding its philosophical and operational goals and perspectives. Lee (2004) goes even further by indicating that only organizations that devise agile, adaptable and aligned supply chains will be able to continue competing in today’s environment. Therefore, observing and measuring the supply chain at all times is critical for today’s organizations. The purpose of this paper is to describe the implementation of a tool called Supply Chain Value Stream Mapping (SCVSM) in order to thoroughly understand competitive priorities of volume and delivery (On-time Delivery (OTD)) for any supply chain in organizations. Design/methodology/approach – An exploratory case study was conducted. Two manufacturing company which have been established in Mexico with a robust supply chain for at least 20 years, were selected. The paper chronicles the implementation of SCVSM in both case studies. Three methods were used to gather data: direct observation; documentary analysis and semi-structured interviews. Findings – This paper proposes a new tool for operation management called SCVSM. Its development, refinement and applied in both case studies. The evidence shows that it is possible to apply the tool (SCVSM) to visualize the variables volume and OTD in supply chains. In consequence, this research has made a small empirical contribution to the theoretical field of supply chain quality management. Research limitations/implications – This paper has the same limitations as all other case-study-based research, including analysis subjectivity and questionable generalization of findings. There may well also be a theoretical gap in the geographic region because the paper only analyzes two companies established in Mexico. Practical implications – Derived to describe both case studies on how to apply the SCVSM tool it may prove to be of value to practitioners and managers involved in the field. Similarly, a section on managerial implications has also been included. Originality/value – The study contributes to the limited existing literature on the Supply Chain Quality Management and subsequently disseminates this information in order to provide impetus, guidance and support toward increasing the development companies in an attempt to move the Mexico manufacturing sector toward world class manufacturing performance.

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