Application of Kaizen Analysis in Automotive Industry: A Case Study

The manufacturing sector has grown significantly during the last two to three decades. Because of the intense competition, customers now place a higher priority on price, delivery time, and product quality. This study employs lean methods and methodologies, including root-cause analysis, kaizen ideas, evaluation of kaizen ideas, and before-and-after comparison, to evaluate the operational performance of the organization. It accomplishes this by using kaizen analysis to assess the level of lean implementation in Indian manufacturing companies. A questionnaire was developed for the goal of collecting data, and industry experts were contacted personally and questioned. According to this study, common implementation of lean practices leads to a reduction of 68% in setup loss, 70% in setup time, 17% in energy consumption, 11% in electricity consumption, 51% in lead time, and an increase of 8.5 times in kaizen per team annually.