RESEARCH ON THE APPLICATION OF THE KAIZEN METHOD TO THE IMPROVEMENT OF THE MANUFACTURING PROCESS IN THE AUTOMOTIVE FIELD

Abstract

In this study we aimed to show the implementation of Lean principles in an international automobile companies and  how one of the most widely used lean tools in the global manufacturing industry, the Kaizen method, is applied to improve the manufacturing process and eliminate various losses by detecting and eliminating the root cause by applying the Plan-Do-Check-Act steps and using various statistical process control methods and different quality tools such as Ishikawa Chart, 5Why, Pareto, 5W+2H, 5S-Standardized work, Visual Management, Visual Check.The deployment of Kaizen is studied in this research. Delivering quality products and services when the customer needs them, in the required quantity, at a fair price, and requiring the least amount of labor, space, equipment, material, and time is known as lean manufacturing, or production at minimal cost without losses. In the automotive industry, the Lean Manufacturing approach has evolved into a survival strategy during the 1980s in an effort to raise production quality. This study started with the presentation of the defect occurred using 5W+2H, then with process mapping using Flowchart Diagram as a first useful tool for viewing activities within a process, and it describes the essential elements of the flow. Therefore, reapplying 6S in workstation and using Fishbone Diagram, Pareto and 5 WHY, the root cause was defined, after identifying the root cause and issues that occurred during the production process, started the principles of implementing Interim Corrective Actions, Permanent Corrective Actions, the monitoring of the results using diagram histogram and finally, work was standardized.