Kaizen results supporting factors in productivity: multiple case study
DOI:
https://doi.org/10.14488/1676-1901.v20i1.3523Keywords:
Kaizen. Continuous Improvement. Productivity. Performance indicators. Support factors of kaizen.Abstract
Kaizen philosophy, despite being considered one of the most effective tools for improving industrial processes, has found it difficult to sustain the long-term improvements. The objective of this article is to analyze the factors that support the results of kaizen in the productivity of the companies, who have implemented kaizen for the long term. The research was based on the multiple case studies with two approaches: quantitative and qualitative. In the quantitative investigation, a longitudinal cut was carried out in a company of the textile segment. The data collected data were obtained from forms, systematic observation of the process, and company reports. In qualitative research, whose temporal cut was transversal, interviews were conducted using a semi-structured questionnaire, in several companies that implemented kaizen for a long term, with a production system equivalent to the textile industry. When comparing the companies, we sought to identify and group the factors considered important by the companies. In addition to identifying the factors that contribute to the sustainability of kaizen improvements, a script was also obtained to help support the results of kaizen in business productivity.Downloads
References
BATEMAN, N. Sustainability: the elusive element of process improvement. International Journal of Operations & Production Management, v. 25, n.3, p. 261-276, 2005. https://doi.org/10.1108/01443570510581862
BATEMAN, N.; RICH, N. Companie’s perception of inhibitors and enablers for process improvement activities. International Journal of Operations & Production Management, v. 23, n.2, p. 185-199, 2003. https://doi.org/10.1108/01443570310458447
BHOI, J. A.; DESAI, D. A.; PATEL, R. M. The Concept & Methodology of Kaizen A Review Paper. International Journal of Engineering Development and Reserch, v. 2, p. 812-820, 2014.
BURCH, M. K. Lean longevity: Kaizen events and determinants of sustainable improvement. 2008, 242 p. Dissertation of Doctor of Philosophy, Ph. D. in Business Administration, Isenberg School of Management, University of Massachusetts, Amherst, USA, 2008.
CAMPOS, V. F. TQC: Controle da qualidade total. 6 ed. Belo Horizonte: Fundação Christiano Ottoni, Escola de Engenharia da UFMG, 1992.
CHAVES FILHO, J. G. B. Melhores práticas para garantia de sustentabilidade de melhorias obtidas através de eventos Kaizen. 2010. 149 p. Dissertação de Mestrado em Engenharia de Produção. (Mestrado Programa de Pós-Graduação em Engenharia de Produção e Área de Concentração em Processos e Gestão de Operações) – Universidade de São Paulo, São Carlos, 2010.
CHEN, J. C.; DUGGER, J.; BOB, H. A. Kaizen based approach for cellular manufacturing system design: A Case Study. The Journal of Tecnology Studies, v. 27, n. 2, 2011. https://doi.org/10.21061/jots.v27i2.a.3
DHONGADE, P. M.; SINGH, M.; SHROUTY, V. A. A review: literature survey for the implementation of Kaizen. International Journal of Engineering and Innovative techonology (IJEIT), v. 3, n.1, p.57-60, 2013.
DONE, A.; VOSS, C.; RYTTER, N. G. Best practice interventions: short-term impact and long-term outcomes. Journal of Operations Management, v. 29, n.5, p.500-513, 2011. https://doi.org/10.1016/j.jom.2010.11.007
DOOLEN, L. T.; AKEN, E. M. V.; FARRIS, J. A.; WORLEY, J. M.; HUWE, J. Kaizen events and organizational performance: a field study. International Journal of Productivity and Performance Management, v. 57, n.8, p. 637-658, 2008. https://doi.org/10.1108/17410400810916062
EISENHARDT, K. M. Building theories form case study research. Academy of Management Review, v. 14, n. 4, p. 532-550, 1989. https://doi.org/10.5465/amr.1989.4308385
FERREIRA, A, S, M. Preparação do sistema produtivo para a filosofia kaizen. 2008, 106 p. Dissertação (Metrado Integrado em Engenharia Mecânica) - FEUP, Porto, 2008.
GAMBHIR, D.; SHARMA, S. Productivity in Indian manufacturing: evidence from the textile industry. Journal of Economic and Administrative Sciences, v. 31, n.2, p.71-85, 2015. https://doi.org/10.1108/JEAS-09-2014-0021
GARCIA, M. J. A.; SABATER, G. J. J.; BONAVIA, T. The impacto of Kaizen events on improving the performance of automotive components’ first-tier suppliers. Int. J. Automotive Technology and Management, v. 9, n. 4, p. 362-376, 2009. https://doi.org/10.1504/IJATM.2009.028524
GARCIA, J. A. M.; VAL, M. P. del.; MARTÍN, T. B. Longitudinal study of the results of continuous improvement in an industry company. Team Performance Management: An International Journal, v. 14, n. 1, p. 56-69, 2008. https://doi.org/10.1108/13527590810860203
GIL, A. C. Como elaborar projetos de pesquisa. 4. ed. São Paulo: Atlas, 2002.
GLOVER, W. J.; LIU, W. H.; FARRIS, J.A.; AKEN, E. M. V. Characteristics of established kaizen events programs: an empirical study. International Journal of Operations & Production Management, v. 33, n. 9, p. 1166-1201, 2013. https://doi.org/10.1108/IJOPM-03-2011-0119
HEDEKER, D.; GIBBONS, R. D. Longitudinal data analysis. Hoboken: John Wiley & Sons, 2006.
HORNBURG, S.; WILL, D. Z.; GARGIONI, P. da C. Introdução da filosofia da melhoria contínua nas fábricas através de eventos Kaizen. In: XXVII ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO, 10., 2007, Foz do Iguaçu. [Anais...] Foz do Iguaçu: ENEGEP, 2007.
IMAI, M. KAIZEN, A. Estratégia para o sucesso competitivo. 5. ed. São Paulo: IMAM, 1994.
JORGENSEN, F.; MATHIESSEN, R.; NIELSEN, J.; JOHANSEN, J. Advances in production management. Advances in Production management Systems, Edited by Olhager, J., Persson, F. Boston: Springer, p. 371–378, 2007.
KARLSSON, C.; AHLSTROM, P. Change process towards lean production: the role of the remuneration system. Internationa Journal of Operation & Production Management, v. 15, n. 1, p. 80-99, 1995. https://doi.org/10.1108/01443579510102918
KING, N. C. de O.; LIMA, E. P.; COSTA, S. E. G. da. Produtividade sistêmica: conceitos e aplicações. Production, Curitiba, v. 24, n. 1, p. 160-176, 2014. https://doi.org/10.1590/S0103-65132013005000006
MA, J. The adoption and implementation of kaizen in Sino-Japanese automotive joint ventures. 2013, 268 p. Tese (Doctor of Philosophy in Operations Management) – Faculty of Humanities and Social Sciences ate Newcastle University, Newcastle University Business School, United Kingdon, 2013.
MAAROF, M. G.; MAHMUD, F. A. Review of contributing factors and challenges in implementing Kaizen in small and medium enterprises. In: 7TH INTERNATIONAL ECONOMICS & BUSINESS MANAGEMENT CONFERENCE, 5th, 6th, 2015. [Anais…] Elsevier: Procedia Economics and Finance, v. 35, p. 522-531, 2016. https://doi.org/10.1016/S2212-5671(16)00065-4
MENARD, S. Handbook of longitudinal research: design, measurements and analysis. San Diego: Academic Press, 2007.
MIGUEL, P. A. C. Estudo de caso na engenharia de produção: estruturação e recomendações para sua condução. Produção, São Carlos, v. 17, n. 1, p. 216-229, 2007. https://doi.org/10.1590/S0103-65132007000100015
MORORÓ, B. O. Modelagem sistêmica do processo de melhoria contínua de processos industriais utilizando o método Seis Sigma e Redes de Petri. 2008, 175 p. Dissertação de Mestrado em Engenharia (Engenharia de Controle e Automação Mecânica) – Universidade de São Paulo, São Paulo, 2008.
OAKLAND, J. S. Gerenciamento da qualidade. Tradução de Adalberto Guedes Pereira. São Paulo: Nobel, 1994.
OPRIME, P. C.; MENDES, G. H. de S.; PIMENTA, M. L. Fatores críticos para a melhoria contínua em indústrias brasileiras. Produção, São Carlos, v. 21, n. 1, p. 1-13, 2011. https://doi.org/10.1590/S0103-65132011005000008
RAVE, J. I. P.; FORERO, D. A. LA ROTTA; GARCÉS, C. A. V. Superando el síndrome del “enemigo externo” em una firma autopartista através del Kaizen. Production, v. 24, n. 4, p. 957-968, 2014. https://doi.org/10.1590/S0103-65132013005000058
ROWLEY, J.; SLACK, F. Conducting a literature review. Management Research News, v. 27, n. 6, p. 31-39, 2004. https://doi.org/10.1108/01409170410784185
SHARMA, A.; MOODY, P. E. A máquina perfeita. São Paulo: Prentice Hall, 2003.
SMADI, S. Al. Kaizen strategy and the drive for competitiveness: challenges and opportunities. International Business Journal, v. 19, n. 3, p. 203-211, 2009. https://doi.org/10.1108/10595420910962070
SOOSAY, C.; NUNES, B.; BENNETT, D.; SOHAL, A.; JABAR, J.; WINROTH, M. Strategies for sustaining manufacturing competitiveness: comparative case studies in Australia and Sweden. Journal of Manufacturing Technology Management, v. 27, n. 1, p. 6-37, 2016. https://doi.org/10.1108/JMTM-04-2014-0043
VASCONCELOS, D. S. C. de; SOUTO, M. do S. M. L. S.; GOMES, M. de L. B.; MESQUITA, A. M. A utilização das ferramentas da qualidade como suporte a melhoria do processo de produção: estudo de caso na indústria têxtil. In: ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO, 29., 2009, Salvador. [Anais...] Salvador: ENEGEP, 2009.
VOSS, C.; TSIKRIKTSIS, N.; FROHLICH, M. Case research in operations management. International Journal of Operations and Production Management, v. 22, n. 2, p. 15-219, 2002. https://doi.org/10.1108/01443570210414329
YIN, R. K. ESTUDO DE CASO. Planejamento e métodos. 2. ed. Porto Alegre: Bookman, 2001.
Published
How to Cite
Issue
Section
License
The Journal reserves the right to make spelling and grammatical changes, aiming to keep a default language, respecting, however, the style of the authors.
The published work is responsibility of the (s) author (s), while the Revista Produção Online is only responsible for the evaluation of the paper. The Revista Produção Online is not responsible for any violations of Law No. 9.610 / 1998, the Copyright Act.
The journal allows the authors to keep the copyright of accepted articles, without restrictions
This work is licensed under a Creative Commons License .
