Use of Kobetsu Kaizen Method to Increase Efficiency in the Production (original) (raw)

Critical Debates in Social Sciences, 2018

Abstract

Purpose: The aim of this study is to reduce the number of rework operations which cause bottlenecks in the production line of a company manufacturing various structural components for the aviation industry and improve the production duration. Design/methodology/approach: Study is implemented by the use of Kobetsu Kaizen (KK) technique is one of the lean management tools. Kaizen technique is a management approach focusing on continuous improvement in operations. Ishikawa diagram and 5W1H (5 Why 1 How) analyses were employed for the detection of root causes. The study is realized at the ABC company, manufacturing products for the aviation industry on an international scale. Results: Rework operations are completely eliminated by the use of the KK technique and improvement of 63,9% was achieved in the relevant process step of the product, where the bottleneck occurred. As a result, the bottleneck of the product was resolved. The company started to operate with the just-in-time manufacturing (JIT) principle by saving on rework costs, extra personnel hours and production time. Research limitations/implications: The company seeks to increase its competitive strength and capacity in the global market. Therefore, technical data used for the statistical assessment of the project cannot be disclosed. Originality/value: KK technique is widely used in various fields just as in the manufacturing industry. This project shows that problems considered to be very complex may be easily and rapidly resolved through the application of KK technique. This study is an authentic project conducted within the aviation industry in Turkey and serves as a bridge between theory and practice in order for KK technique to be comprehended in more detail.

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