Thousands of little & medium scale markets are present in India. All are dealing with Specific troubles causing shortage of manufacturing as well as high quality problems. This 10 case study deals with the kaizen implementation in an industry in an assembly line in India.

1. 1
KAIZEN 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%

2. 2
KAIZEN 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%

3. 3
KAIZEN 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%

4. 4
KAIZEN 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%

5. 5
KAIZEN 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%

6. 6
KAIZEN 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%

7. 7
KAIZEN 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%

8. 8
KAIZEN and GEMBAKAIZEN
are the trademarks of KAIZEN Institute
Aircraft Electricals EOU
Performance
Indicator
Benefit
Realized
Quantum of
Improvement
Throughput time (& Inventory) Reduced 48%

9. 9
KAIZEN 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%

10. 10
KAIZEN 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%