10 case studies for kaizen implementation

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%

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%

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%

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%

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%

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%

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%

8KAIZEN and GEMBAKAIZEN

are the trademarks of KAIZEN Institute

Aircraft Electricals EOU

Performance Indicator

Benefit Realized

Quantum of Improvement

Throughput time (& Inventory) Reduced 48%

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%

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%