APPLICATION OF LEAN-KAIZEN CONCEPT FOR IMPROVING QUALITY SYSTEM OF MANUFACTURING FIRMS

Authors

  • Sunil Kumar Maharshi Dayand University
  • Ashwani Kumar Dhingra Mechanical Engineering Department, University Institute of Engineering & Technology, Maharshi Dayanand University, Rohtak-124001, Haryana, INDIA
  • Bhim Singh Mechanical Engineering Department, Sharda University, Greater Noida – 201306, Uttar Pradesh, INDIA

DOI:

https://doi.org/10.23055/ijietap.2021.28.5.3540

Keywords:

Lean-Kaizen, data envelopment analysis, quality system, small and medium size enterprises

Abstract

This research paper demonstrates a case study of improving the quality system for ten small and medium-size fastener manufacturing industries by applying the Lean-Kaizen using data envelopment analysis (DEA) technique. The data has been composed by paying personal visits to the selected industries over three months for primarily two inputs (manpower and quality cost) and one output (on-time delivery). The efficiency score of the selected industries has been calculated through the constant returns to scale (CRS), Charnes Cooper & Rhodes (CCR) model having the most efficient industry as a benchmark. The input minimization is considered an objective function to explore the possibilities of input reduction. The Lean-Kaizen concept was to identify the slackness/ gap areas within the inputs with the 5-why method for eliminating the waste and identifying the root cause of the gap areas and Kaizen events. After applying the Kaizen events, the DEA CCR model has been used to analyze the collected data with improvement in efficiency score as findings for the selected industries. Out of ten selected industries,100% efficiency in the quality system has been reported in two industries with 9% to 52% enhancement in others. The study will be helpful to the managers and academicians to overcome the different inefficiencies in the organizations.

Author Biographies

Sunil Kumar, Maharshi Dayand University

Sunil Kumar is a Ph.D Research Scholar at the Department of Mechanical Engineering of University Institute of Engineering & Technology in Maharshi Dayanand University, Rohtak, Haryana, India. His research interests include continuous improvement, total quality management, lean manufacturing and quality management system. He published papers in several national conferences. Corresponding author. Email: sunil.panchal2007@gmail.com

Ashwani Kumar Dhingra, Mechanical Engineering Department, University Institute of Engineering & Technology, Maharshi Dayanand University, Rohtak-124001, Haryana, INDIA

Dr. Ashwani K. Dhingra is working as an Associate Professor & Head, Department of Mechanical Engineering, University Institute of Engineering & Technology of Maharshi Dayanand University Rohtak-124001 Haryana INDIA. He had obtained Doctorate Degree in Mechanical Engineering from National Institute of Technology Kurukshetra-136119 Haryana INDIA along with Master Degree in Mechanical Engineering from Panjab Engineering College Chandigarh. He has published number of research articles in different journals of repute. He had also received young scientist award for international conference abroad twice from Department of Science & Technology New Delhi. He is also supervising number of students for the Ph.D degree and having more than 12 years of teaching/research experience. His research interest includes, operation management, lean manufacturing, Advanced machining, Metaheuristics, Biofuels etc. 

Bhim Singh, Mechanical Engineering Department, Sharda University, Greater Noida – 201306, Uttar Pradesh, INDIA

Dr. Bhim Singh is presently associated with Sharda Univsersity, Greater Noida, Uttar Pradesh, India as a Director Principal and Professor of Mechanical Engineering. He holds a Ph.D degree in Mechanical Engineering (Lean Manufacturing) from National Institute of Technology, Kurukshetra. He has published many research papers in various journals of repute. He has received best reviewer award in 2010 and outstanding paper award in 2011 from Emerald Insight. He has delivered invited talks / key-note speeches in various conferences in India and abroad. His research area is statistical quality control, operation management, supply chain management and lean manufacturing. 

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Published

2022-01-04

How to Cite

Kumar, S., Dhingra, A. K., & Singh, B. (2022). APPLICATION OF LEAN-KAIZEN CONCEPT FOR IMPROVING QUALITY SYSTEM OF MANUFACTURING FIRMS. International Journal of Industrial Engineering: Theory, Applications and Practice, 28(5). https://doi.org/10.23055/ijietap.2021.28.5.3540

Issue

Vol. 28 No. 5 (2021)

Section

Product Design and Development

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