Investigating methods and challenges of Kaizen execution: a case study of an engineering firm in Pakistan

KAIZEN is a system of a continuous endeavor by an organization to improve its business activities and processes, the goal being to improve the quality of products and services so that the organization can meet full customer satisfaction. Kaizen can be an integrated and company-wide approach through collaboration of all the levels of the organization: top management, middle managers and front-line employees. Commitment, genuine participation and motivation of all the three actors are critical factors. The purpose of this study is to assess the methods and challenges faced by ABC Engineering Pvt., Ltd. in executing and sustaining kaizen. Quality circles were established and the 5S’s were deployed as a beginning of kaizen execution in the firm.This is descriptive research, and its basic aim is to explore and gain additional information about the subject area and to identify areas for further investigation. The study used clustered sampling for the data collection. Top management commitment in building and sustaining a continuous improvement culture, clear communication channels, involvement of all members of the company, training in kaizen methodologies as well as fair and equitable motivational schemes including empowerment has a great impact on the effectiveness of kaizen practices. However, the levels of all the above mentioned factors were not well practiced in ABC Engineering Pvt., Ltd. for ingraining the culture of kaizen. Most of the participants (employees) were dissatisfied with the applications of the above mentioned factors of Kaizen as practiced in the firm.