Enhancing productivity and efficiency in electrical device manufacturing: a case study on leveraging rapid improvement events (RIEs) and lean tools

Purpose This study aims to demonstrate and evaluate a structured three-stage rapid improvement event (RIE) methodology for diagnosing, implementing and sustaining operational improvements in manufacturing environments. A semi-automated electrical device manufacturing process is used as an illustrative case study to validate the approach. Design/methodology/approach The study applies a RIE structured around the three-stage Kaizen methodology (Pre-Kaizen, Kaizen, Post-Kaizen). The approach includes Gemba observation, process mapping, time studies, Yamazumi analysis, root cause analysis, rapid experimentation and immediate implementation of solutions. A cross-functional team executed the event over a short, intensive period to achieve fast, measurable improvements. Findings The implemented process improvements resulted in significant enhancements across various aspects of the production line. These improvements led to a more balanced workload between processes, highlighted by reduced cycle times and increased operator utilization. The average hourly throughput increased by over 40%, while the throughput per labor hour more than doubled. Additionally, reducing rejection rates from 6.34% to 1.3% and eliminating overtime expenses resulted in substantial cost savings. The optimization of labor utilization also led to significant annual savings in labor costs. These changes were implemented without job losses, with affected employees relocated to other positions as part of the company’s commitment to its workforce. Originality/value This study contributes to the literature by demonstrating the application of a structured three-stage RIE in a semi-automated manufacturing environment – an area with limited empirical evidence. By integrating Lean tools such as Gemba observation, Yamazumi analysis and Takt time evaluation within an RIE framework, the study provides a replicable model for achieving rapid, high-impact improvements without major capital investment. The findings offer new insights into how RIEs can effectively address performance issues in hybrid manual-automated processes.