10 case studies for kaizen implementation

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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%



Pharmaceutical I

Industry Details Performance Indicator

Benefit Realized


Tablets Yield Enhanced By 2.1% to reach 99.6%

Lyophilization Capacity Increased Without Investment

80%

Vaccine Packing Line Productivity Increased 30%



Pharmaceutical II

Industry Details Performance Indicator

Benefit Realized


Vial Packing Manpower Productivity Increased 32%

PFS Packing Manpower Productivity Increased 92%



Stainless Steel Tube Manufacturer


Benefit Realized


OEE(Overall Equipment Efficiency)

Improved From 46% to 66%

Capacity Increased without Investment 44%



Plastic Thermoware Manufacturers


Benefit Realized


Assembly Productivity Went up 250%!!

Floor space in assembly Reduced 60%



Garment Industry


Benefit Realized


Manpower Productivity Went up 90%

Space used Reduced by 30%



Precision Automotive & Aerospace Components Manufacturer


Benefit Realized


Manpower productivity Went up 25%

Space required Reduced by 17%

Manufacturing Costs Went down 31%



Aircraft Electricals EOU


Benefit Realized


Throughput time (& Inventory) Reduced 48%



Rubber Products


Benefit Realized


Manpower Productivity Went up 38%

Material Wastage Reduced 37%

Order to Delivery time Went down 67%

Market Share Went up From 34% to 48%



Automotive Ancillary


Benefit Realized


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%

10 case studies for kaizen implementation

Business