Implementation of Integrated PDCA-Kaizen in the Plastic Converting Machinery Manufacturing Industry

Implementation of Integrated PDCA-Kaizen in the Plastic Converting Machinery Manufacturing Industry
  IJETT-book-cover           
  
© 2023 by IJETT Journal
Volume-71 Issue-11
Year of Publication : 2023
Author : Amitkumar Dhanjibhai Makwana, Gajanan Shankarrao Patange, Vishal Mehta, Amarishkumar J. Patel
DOI : 10.14445/22315381/IJETT-V71I11P212

How to Cite?

Amitkumar Dhanjibhai Makwana, Gajanan Shankarrao Patange, Vishal Mehta, Amarishkumar J. Patel, "Implementation of Integrated PDCA-Kaizen in the Plastic Converting Machinery Manufacturing Industry," International Journal of Engineering Trends and Technology, vol. 71, no. 11, pp. 116-123, 2023. Crossref, https://doi.org/10.14445/22315381/IJETT-V71I11P212

Abstract
In this dynamic and ever-evolving world, nothing but change and continuous improvement are the two key drivers for the excellence and success of the business. All industry leaders and market players have one thing in common: they continuously improve the business's current process or product. Continuous improvement in performance parameters gives the cutting edge to the business. Kaizen is the most frequently used methodology in the manufacturing sector and remains an appropriate improvement tool. This study explores integrating the Plan-Do-Check-Act (PDCA) cycle with Kaizen to improve the productivity and quality of products and components of plastic-converting machinery companies. By implementing integrated PDCA–Kaizen, it was found that the productivity of assembly of bearing housing has increased by 41.66%, and the assembly time has reduced to 10.48 min. Also, with the help of integrated PDCA-Kaizen, defects were eliminated for the side sealing (SS-800) machine.

Keywords
Kaizen, Lean manufacturing, Plan-Do-Check-Act, Productivity improvement, Why-Why analysis.

References
[1] A.D. Peterson, and J.F. Chin, “A Collaborative Scheme with Vendor in Kaizen,” IOP Conference Series: Materials Science and Engineering, vol. 530, pp. 1-9, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[2] Ganesh S. Jadhav et al., “Role of Kaizens to Improve Productivity: A Case Study,” Applied Mechanics and Materials, vol. 592-594, pp. 2689-2693, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Heru Darmawan, Sawarni Hasibuan, and Humiras Hardi Purba, “Application of Kaizen Concept with 8 Steps PDCA to Reduce in Line Defect at Pasting Process: A Case Study in Automotive Battery,” International Journal of Advances in Scientific Research and Engineering (IJASRE), vol. 4, no. 8, pp. 97-107, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[4] Kong Siew Mui, Rajendran Muthuveloo, and Josephine Chan Ie Lyn, “Kaizen Culture: Double the Good, Half the Bad Perspective of Electrical & Electronics Manufacturers,” International Journal of Law, Government and Communication (IJLGC), vol. 7, no 29, pp. 27- 43, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[5] Laban Gasper, and Beny Mwenda, “Quantitative Analysis of Kaizen Philosophy on Productivity Improvement,” International Journal of Research in Business and Social Science, vol. 12, no. 3, pp. 557-562, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[6] Mahmut Tekin et al., “An Application of Kaizen in a Large-Scale Business,” Proceedings of the International Symposium for Production Research 2018, pp. 515-529, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Mohd Fazli Mohd Sam, Budi Suprapto, and Kamarudin Abu Bakar, “Application of Lean Manufacturing Tools: The Impact on Kaizen and Product Defection in Packaging Companies,” Intelligent Manufacturing and Mechatronics, pp. 424-433, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[8] B. Mwenda, and L. Gasper, “Kaizen Approach to Quality Improvement and its Financial Implication,” African Journal of Applied Research, vol. 8, no. 2, pp. 394-405, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[9] S. Saravanane et al., “A Proposed Model for Productivity Improvement by Implementation of Lean Manufacturing Techniques in a Textile Industry,” SSRG International Journal of Mechanical Engineering, vol. 10, no. 8, pp. 31-48, 2023.
[CrossRef] [Publisher Link]
[10] Haftu Hailu, and Tewedros Hailu, “Reduction of Long Delivery Time by Implementing Advanced Kaizen (Problem Solving Approach),” SSRG International Journal of Industrial Engineering, vol. 4, no. 3, pp. 26-48, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[11] Saima Akter, Farasat Raiyan Yasmin, and Md. Ariful Ferdous, “Implementation of Kaizen for Continuous Improvement of Productivity in Garment Industry in Bangladesh,” American Academic and Scholarly Research Journal, vol. 7, no. 3, pp. 229-243, 2015.
[Google Scholar] [Publisher Link]
[12] PDCA, Wikipedia Website. [Online]. Available: https://en.wikipedia.org/wiki/PDCA
[13] Nitesh Verma et al., “To Study the Implementation of Kaizen in Northern Indian Manufacturing Industries,” Recent Advances in Mechanical Engineering, pp. 465-474, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[14] Puneet Sharma, Neeraj Kumar Sharma, and M.P. Singh, “Process Improvement by Implementation of Kaizen as a Quality Tool within Defined Constraints: A Case Study in Manufacturing Industry,” MATTER: International Journal of Science and Technology, vol. 1, no. 1, pp. 182-194, 2015.
[CrossRef] [Google Scholar] [Publisher Link]