Implementation of Lean Manufacturing through Supplier Kaizen Framework - A Case Study

Hazri M. Rusli and Ahmed Jaffar

Faculty of Mechanical Engineering

Universiti Teknologi Mara

Shah Alam, Selangor 40450, Malaysia

Suzilawati Muhamud-Kayat and Mohd Tarmizi Ali

Faculty of Electrical Engineering

Universiti Teknologi Mara

Shah Alam, Selangor 40450, Malaysia

Kaizen 32

Abstract

Lean manufacturing is a production philosophy derived from the Toyota Production System (TPS). It has the ultimate aim of reducing cost by thoroughly eliminating wastes. Lean manufacturing aims to improve productivity and creating continuous flow in the production and strive to create value in the every aspect of the production. This paper studies on the implementation a Lean Manufacturing project done at an automotive component company. The Lean project uses the Supplier Kaizen framework- steps and methodology to implement the lean manufacturing at a Malaysian components manufacturer through kaikaku and kaizen approach. This resulted in substantial improvements in quality, timely delivery and cost saving which in total improves the bottom line. 

Keywords Lean manufacturing, Kaikaku-kaizen, Supplier Kaizen framework