Kaizen Planning, Implementing and Controlling

330 Pages·2017·4.58 MB·English

Management and Industrial Engineering
Jorge Luis García-Alcaraz
Midiala Oropesa-Vento
Aidé Aracely Maldonado-Macías
Kaizen
Planning,
Implementing
and Controlling
Management and Industrial Engineering
Series editor
J. Paulo Davim, Aveiro, Portugal
More information about this series at http://www.springer.com/series/11690
í
Jorge Luis Garc a-Alcaraz
Midiala Oropesa-Vento
é í
Aid Aracely Maldonado-Mac as
Kaizen Planning,
Implementing
and Controlling
123
Jorge LuisGarcía-Alcaraz AidéAracely Maldonado-Macías
Department ofIndustrial Engineering Department ofIndustrial Engineering
andManufacturing,Institute andManufacturing,Institute
ofEngineering andTechnology ofEngineering andTechnology
AutonomousUniversity ofCiudad Juarez AutonomousUniversity ofCiudad Juarez
CiudadJuárez,Chihuahua CiudadJuárez,Chihuahua
Mexico Mexico
Midiala Oropesa-Vento
Department ofIndustrial Engineering
andManufacturing,Institute
ofEngineering andTechnology
AutonomousUniversity ofCiudad Juarez
CiudadJuárez,Chihuahua
Mexico
ISSN 2365-0532 ISSN 2365-0540 (electronic)
ManagementandIndustrial Engineering
ISBN978-3-319-47746-6 ISBN978-3-319-47747-3 (eBook)
DOI 10.1007/978-3-319-47747-3
LibraryofCongressControlNumber:2016955787
©SpringerInternationalPublishingAG2017
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Humans take inspiration when they set a
goal. To me, my family is my inspiration,
which is why I dedicate this book to:
God. I thank Him for everything.
My parents, my life teachers.
My son, Jorge Andres García-Rodríguez,
who has taught me how to be a father.
My nine-year-old daughter, Mariana Odette
García-Rodriguez, who spent her entire
summer vacation by my side in this project.
My wife, Ana Blanca Rodriguez-Rendon,
for her unconditional support in all the
projects I undertake.
My brothers and sisters, who taught me the
best lessons at home.
Jorge Luis García-Alcaraz
IfirstdedicatethisbooktoGod.IthankHimfor
his infinite goodness andmercy, and for
helpingmecomesofarandreachallmygoals.
Also, I would liketo dedicate this work to:
My daughters Celia y Nadelis; they are my
source of inspiration and the compass
guiding my life.
My parents, who guide my steps from heaven.
My sister, for her wholehearted support.
Without her, this work would be much
impaired.
My entire family, friends, and colleagues,
who always and unconditionally offer me
kindness and friendship.
Midiala Oropesa-Vento
I dedicate this book to my family, my
colleagues and students. I thank every
experience gained and every moment shared
with them to accomplish this goal. For the
future challenges and the great pleasure to
work together.
Aidé Aracely Maldonado-Macías
Foreword
Since the 1960s, Mexico has experienced increased industrialization. Such growth
has been supported by the Maquiladora Program and the North American Free
Trade Agreement (NAFTA), through which foreign-owned companies, mainly
from the United States and Canada, settle in the Mexican territory.
The northern Mexican border became one of the most favored regions. More
specifically,incitiessuchasTijuana,Mexicali(BajaCalifornia),andCiudadJuárez
(Chihuahua) the growth of manufacturing companies—or maquiladoras—sky-
rocketed. Maquiladoras, also known as maquiladoras, are factories importing a
great amount of raw material and equipment and exporting final products around
the world.
Maquiladoras arrive in Mexico with high technological and methodological
manufacturingtools.Oneofthemostimportantoftheseproductionmethodsislean
manufacturing (LM). LM is a set of tools for the elimination of waste along the
production process, focusing on error detection, cost reduction, and increased
efficiency. However, the main issue with LM techniques and methods is their
cultural implications.
LMphilosophiesemergedinEasterncompanies;consequently,theirapplication
in the Western industry often poses some problems, and sometimes the expected
benefitsarenotobtained. Inthat sense,Kaizen isanLMtoolthathasgainedmore
territory during the last years, yet its implementation is still challenging to the
Western world. To address this gap for the Mexican industry, this work identifies
the critical success factors (CSFs) for Kaizen implementation and associates them
with the benefits obtained by Mexican manufacturing companies.
The book contains13 chapters grouped into five sections. In Chap. 1 we define
lean manufacturing, discuss the tools that form the lean production system, and
addressKaizenasaLMtool.Thischapterisgeneric,asitbrieflydescribeseachLM
tool but also aims at relating them. Then, the chapter analyzes past and current
works on Kaizen, provides an overview of its main benefits, and discusses the
objectives and limitations of this research.
vii
viii Foreword
Chapter 2 provides an extensive literature review of Kaizen, where 235 articles
arestatisticallyanalyzed.Thereviewisaddressedfromdifferentperspectives.First,
we examine Kaizen research per years of publication, highlighting the increasing
trend in Kaizen research during the last years. Second, we report the leading
journalsandmagazinesinKaizenpublication,andclassifyresearchpapersbasedon
thecountryoforigin.Similarly,graphsdepictthedistributionofKaizenresearchby
considering leading universities, departments, and the most prominent industrial
subsectors.
Chapter 3 is one of the most important. It divides Kaizen implementation into
three phases: planning, execution, and control. Then, it discusses critical success
factors(CSFs)ateachphaseandexaminesthetypeofKaizenbenefits—economic,
competitive, and for human resources—that can be obtained from Kaizen imple-
mentation. Readers are strongly encouraged to carefully review this chapter since
understanding each one of the elements addressed is central for interpreting the
models proposed in the last three chapters.
Chapter 4discusses theresearchmethodologyfollowedinorder todevelopand
test the structural equation models that relate Kaizen critical success factors with
Kaizen benefits. The chapter also explains the survey construction and adminis-
trationprocesses,aswellasthedatacaptureandanalysisprocedures,includingdata
screening and validation. Then, the chapter briefly explains the information vali-
dation process, as well as the descriptive analysis of items. Finally, the last part of
thischaptersummarizeshowstructuralequationmodelsareevaluatedtodetermine
their efficiency
Chapter 5 is the first chapter reporting findings from data gathered in the
manufacturingindustryofCiudadJuárez.Thedescriptiveanalysisofthesampleis
summarized by highlighting the surveyed industrial subsectors, as well as the size
of companies, the gender of participants, their work experience, and their job
positions.
Chapters 6–8 discuss the descriptive analysis of the items at the three Kaizen
implementation phases (planning, execution, and control). Each analyzed item
showsamedianvalueasthemeasureofcentraltendencyandaninterquartilerange
(IQR) value, considered as the measure of data dispersion. A similar analysis is
carried out to Kaizen benefits in Chap. 9, where benefits are sorted based on their
medianvalue.Benefitswiththehighestmedianvalue indicatethattheyarealways
obtained in the manufacturing industry of Ciudad Juárez.
Chapter 10 details the validation process of the observed variables. Since these
variables are integrated into latent variables, we make use of theCronbach’salpha
indextodeterminewhethertheyshouldremaininthelatentvariablesoroughttobe
removed in order to increase internal consistency of the dimensions. Internal
consistency validation is important since models proposed in the following three
chapters are based on the analyzed latent variables.
Chapters 11–13 propose a series of models to interpret and assess the relation-
ship between every Kaizen implementation phase and the benefits obtained in the
manufacturing sector of Ciudad Juárez, Chihuahua. Every chapter includes three
models. The first two analyze four latent variables each, two of them concerning
Foreword ix
Kaizen activities at the different implementation phases. However, the third
model of each chapter integrates, through a second-order factor analysis, Kaizen
implementation latent variables into a single latent variable, depending on the
implementationphasestudied.Thepurposeofthisintegrativemodelistoprovidea
general overview of the relationship between every Kaizen implementation phase
and the economic benefits.
Carlos Javierre Lardies
Department of Mechanical Engineering
Universidad of Zaragoza, Spain