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Results of Kaizen methodology implementation in manufacturing

Examples of Japanese business philosophy based on the Toyota Production System (TPS) show that Japanese carmakers, despite occasional crises and changes in trends on the global market, managed to achieve flexibility of production systems by which they can quickly and effectively adapt to changing consumer needs and requirements of individual market segments. To meet the needs of the consumers and on this basis ensure the survival and growth on the market, Japanese companies use a systematic approach to continually examine their operations and implement techniques of everyday advancement and improvement of business systems. Most of the successful, global companies such as already mentioned Toyota, then Honda, Nissan and Sony, are applying in their operations the Kaizen methodology based on incremental improvements of existing systems that do not require large investments. The starting hypothesis assumes that it is possible to implement the Kaizen methodology, in an adapted form, in a domestic business entity and through its application improve the company's business in the long term. The results of applying the Kaizen methodology were systematically observed and recorded over a period of five years, and point to the fact that during the observation period 94 Kaizen activities in the form of small projects were conducted which resulted in increased revenue per employee of 61% while also increasing the number of employees.

Kaizen ; PDCA ; manufacturing improvement ; cost reduction ; process approach

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