10 Case Studies for Kaizen Implementation

1
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
2
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
3
Pharmaceutical II
Industry Details Performance Indicator Benefit Realized Quantum of Improvement
Vial Packing Manpower Productivity Increased 32
PFS Packing Manpower Productivity Increased 92
4
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
5
Plastic Thermoware Manufacturers
Performance Indicator Benefit Realized Quantum of Improvement
Assembly Productivity Went up 250!!
Floor space in assembly Reduced 60
6
Garment Industry
Performance Indicator Benefit Realized Quantum of Improvement
Manpower Productivity Went up 90
Space used Reduced by 30
7
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
8
Aircraft Electricals EOU
Performance Indicator Benefit Realized Quantum of Improvement
Throughput time ( Inventory) Reduced 48
9
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
10
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