Philippine E-Journals

Productivity Improvement in Final Visual Inspection Process at Gunma Gohkin Philippines Corporation using Kaizen Technique

Diether John Javier | Jeson Aaron Lorenzana | James Carl Macalalad | Cyril Magalong | Ryan Jeffrey Curbano

 

Abstract:

Lean manufacturing tools are used by various automotive industries in today’s competitive world since the goal is to reduce waste in the whole process through incremental improvements to be more effective and more efficient. Hence, the purpose of this study is to identify and demonstrate, how non-value-added activities affect the productivity of the process. Furthermore, the study follows an applied research design since specific questions were answered with direct applications and an action, technique, or plan was deliberately presented and a result was seen. At the beginning of this study, lean tools, time study, and systematic questioning techniques were used to retrieve relevant data from the process and were analyzed. Consequently, from the observed results, it significantly showed that the cycle time was reduced from 247.30 seconds to 105.99 seconds and non-value-added activities were reduced by 34 percent. Furthermore, the output per day increased by 25 percent, process cycle efficiency increased by 12 percent, and the value-added time was reduced by 52 percent. Actual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of a prototype.