As a Kaizen event facilitator, I had the opportunity to work with a team of 12 people from the purchasing and material departments of a manufacturing company. The purpose of the Kaizen event was to streamline the aluminum extrusion ordering process with production. In this case study, I will outline the problem statement, the steps we followed, the improvements we proposed, and the results we achieved.
Problem Statement:
The manufacturing company was experiencing delays in production due to issues with the aluminum extrusion ordering process. There were communication gaps between the purchasing and material departments, leading to a lack of clarity in the ordering process. The lack of clear communication and standardization resulted in delays, confusion, and errors in the ordering process, ultimately leading to production delays.
Kaizen Event Part 1: Define the Problem Statement, Identify and List Out the Root Causes, and Map the Current Process.
The team and I analyzed the current ordering process and identified several issues that were leading to delays in production. We found that communication between the purchasing and material departments was poor and that there was a lack of clarity in the ordering process. We developed a current process map that highlighted the bottlenecks and inefficiencies in the process, including the time required to obtain materials and the difficulty in identifying the correct materials for each job.
Through our analysis, we were able to identify the root causes of these issues, which included a lack of communication, unclear procedures, and a lack of standardization. We also identified the potential for errors in the process, which could lead to further delays in production.
Kaizen Event Part 2: Discuss the Problems at All Stages and Propose Improvements. List Out All the Action Item, Assign Task Along With Due Date. Map Out the Future State.
During our second event, we discussed the problems at all stages of the ordering process and proposed improvements. We developed a list of action items and assigned tasks along with due dates. We also mapped out the future state of the process and developed a plan to implement the proposed improvements.
The team and I proposed several improvements to the ordering process, including the development of standard operating procedures, the creation of clear communication channels, and the implementation of a material review board to ensure that the correct materials were being ordered for each job.
To implement these improvements, we created a clear and concise set of standard operating procedures that outlined the ordering process from start to finish. The procedures were designed to eliminate the potential for errors and misunderstandings that could occur during the ordering process. The procedures were communicated clearly to everyone involved in the ordering process, ensuring that everyone was on the same page and understood their role in the process.
We also created clear communication channels between the purchasing and material departments, ensuring that everyone was aware of the status of each order and any issues that needed to be addressed. This helped to eliminate delays and misunderstandings that could occur when communication was poor.
Finally, we implemented a material review board to ensure that the correct materials were being ordered for each job. This helped to eliminate errors and delays that could occur when the wrong materials were ordered.
Results:
The improvements that were implemented helped to streamline the ordering process and reduce lead times by 30%. The improvements also helped to improve the quality of the final product, as the correct materials were now being ordered for each job. The improvements led to increased customer satisfaction and higher productivity, as production times were significantly reduced.
Lessons Learned:
As a Kaizen event facilitator, I learned several important lessons during this project. First, it is essential to take a collaborative approach and involve all stakeholders in the process. In this project, we were able to achieve significant results by working closely with the purchasing and material departments to identify the root causes of inefficiencies and develop a plan to implement improvements.
Second, it is important to communicate the goals and objectives of the project clearly. By doing so, we were able to ensure that everyone was on the same page and understood their role in the process. This helped to build trust and ensure that everyone was committed to the project.
Third, it is important to map out the future state of the process and develop a plan to implement the proposed improvements.
DALAL'S 