The effects of the application of the Kaizen methodology in an automobile industry

Abstract

The present work had as objective to analyze the effects of the application of the Kaizen methodology in the reduction of losses and wastes in a deficit productive process. The research and implementation of the project were carried out in the area of Stamping with a “Tandem” process (manual process), which was identified as the main loss related to the NVAA movements (activi ties that do not add value). We used the Kaizen methodology and the application of tools such as 5S, Yamazumi, PDCA Cycle and 3Ms. On-site observations were made in the organization, with the objective of collecting and recording the facts of reality. Automation of a process was perfor med, passing a totally manual “Tandem” production line, to a robotized “Transfer” process, more unstable and with a productivity increase of 464%. The results were: increased productivity, reduc tion of movement, ergonomic improvements, reduction of unsafe conditions, reduction of stock, reduction of labor, standardization of work, improvements in quality and organization of the job.