Productivity Improvement by Application of Kaizen in Assembly Line: A Case Study in Automotive Industry

The main objective of manufacturing industries is to increase productivity with high quality. Right now, many companies are facing problems such as high-quality rejection, unnecessary shifting, and high production costs. However, the ambiguity still lies in the selection of an appropriate tool’s Kaizen to reduce waste. Kaizen refers to increasing productivity, efficiency, and performance through the process of eliminating MUDA (unnecessary movements, surface) through small continuous process improvements.This paper proposed the implementation of Kaizen tools in assembly line balancing, and the main objective is to show how Kaizen can help to eliminate MUDA and ameliorate the efficiency of assembly lines. The outcome of this case study is the improvement of efficiency from 73.16% to 89.29% and the elimination of 3 operators.