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EN
Purpose: A significant source of information regarding product quality for a company is the complaints lodged by customers. The analysis of complaints can provide the company with valuable insights. Therefore, the objective of this study is to analyze complaints from a one-month period within a company manufacturing baby strollers. The analysis of complaints was conducted to identify areas within the studied company where discrepancies occur, enabling appropriate corrective actions to be implemented. Design/methodology/approach: The Pareto chart was utilized to conduct the analysis of complaints, illustrating the group of most significant issues. To delve into the root cause of the problem, a task force team employed the 5 Whys method. In the article, based on conducted literature reviews, a theoretical description of quality management tools and methods such as the Pareto chart, the 5 Whys method, Kaizen philosophy, teamwork, and additionally, information regarding product quality and safety can be found. Findings: During the course of our work, the source of failures within the company was identified. The major issue turned out to be haste, affecting both the production staff and an external company collaborating with the enterprise. As part of the corrective actions, a motivational system was implemented for employees, and piecework norms were established within the company. Additionally, an innovative solution was applied in the examined enterprise through the design and creation of pattern books for inter-process control within the company and final inspection at the crossbar flat supplier. The proposed problem-solving methods within the enterprise can be applicable for future endeavors. Research limitations/implications: The study was conducted over a short period of time due to the urgent need to address existing issues within the company. It can be inferred that if a longer time frame were taken into account, it would be possible to identify additional causes of discrepancies. Originality/value: The obtained results can serve as a valuable source of information for other companies manufacturing baby strollers, which are seeking to their own issues.
2
Content available Application of Kaizen and kaizen costing in SMEs
EN
The research problem revolves around an attempt to answer the questions: “Are enterprises from the SME sector interested in implementing strategic management accounting instruments, including Kaizen Costing? Is Kaizen Costing more widely used in SMEs operating in Poland?" The aim of the article is therefore to highlight the importance of Kaizen and Kaizen Costing and to draw attention to how much support these solutions can be for SMEs in the current social, economic, and environmental conditions. The article presents the results of surveys conducted in this regard. The accomplishment of the established objective of the work required conducting a review of the literature on the subject and presenting conclusions from previous own research in the above respect. The method of participant observation, critical analysis and synthesis was used in the study. According to the research results, there is little interest in these instruments in large enterprises, however, in medium-sized enterprises, the interest and degree of application of Kaizen and Kaizen Costing is negligible. The research results indicate the need for further development and broadening the dialogue on the usability and benefits which enterprises, in particular SMEs, may derive from the introduction of such innovative solutions.
EN
Purpose: The fourth industrial revolution has a strong influence on changes in enterprises towards smart manufacturing. Technological progress and digital economies created new conditions for business. Currently producers aiming at digitalization of processes and smart manufacturing based on key technologies (pillars) of Industry 4.0. In transformation process, the question arises, from what to start the changes and which path to choose to smart manufacturing (SM). Apart from big projects of SM, changes need the concept of Kaizen based on small steps of changes on workstations towards smart production. The purpose of the paper is the presentation of links between Smart Manufacturing (SM) projects and Kaizen. Design/methodology/approach: The paper was realized based on literature review and examples of SM projects. Findings: The study found that Kaizen is evolving with the automation and digitisation of production. IC technologies facilitate Kaizen improvements. The automation of production processes provides insight into historical data through process monitoring. Fully autonomous equipment is equipped with systems for transferring data to a central decision-making system. The machine operator's job is to collaborate with robots and control machine operation in real time using simple data visualisation and warning systems. Research limitations/implications: The work prepared is of a high degree of generality. Kaizen is implemented at workplaces and is concerned with practical improvements. These improvements are many, following the principle of small steps. The publication focuses on presenting the idea of Kaizen in SM projects. Practical implications: The paper can have an impact on the practical application of Kaizen in SM projects as it presents examples of Kaizen improvements. Originality/value The topic of adapting Kaizen to SM projects is a new area of research that will be strongly built upon due to the utility of Smart Kaizen.
EN
Kaizen has long been known as an improvement philosophy that starts with small frequent changes to make larger changes in production. These changes come from the ideas and creative thinking of employees to ensure that the production conditions and processes are continuously improved. However, Kaizen not only helps motivate employees to think creatively with effective methods and skills, but it also helps them develop their capabilities, personality, and good work habits. The purpose of this paper is to show a new approach to human resources quality improvement through the Kaizen philosophy as a sustainable and active strategy to improve work performance. With analytical research on the relationship between Kaizen implementation, human resources quality improvement, and production efficiency and exploratory research on particular cases in manufacturing enterprises in Vietnam, the authors point out changes in production efficiency and human capacity before and after implementing improvement (Kaizen) projects. The paper finds significant changes of employee capability (Kaizen practitioners) after evaluating the human resource development process on the basis of six indicators of two groups (namely capacity development, personality development) and a set of criteria using a 5-point scale. In addition, the paper proposes a PDCA based framework with 12 contents corresponding to stages of the human resource development. This paper extends theories related to Lean Manufacturing or Kaizen, highlighting how philosophy of Kaizen has hard and soft impacts on the improvement of performance and human resources.
5
Content available remote Nowe role mechanika TPM
PL
Decydując się na wdrożenie TPM, a co za tym idzie - podniesienie efektywności parku maszynowego - decydujemy się też na zmianę dotychczasowych obowiązków dla wielu osób. To bardzo ważne, żeby mieć świadomość, że zarówno operator, jak i mechanik będą mieć nowe zadania, nowe obowiązki, nowe odpowiedzialności, ale też i nowe prawa.
EN
In times of innovation, rapid economic development and high competition, each producer tries to improve the condition of his company. Then the quality of services or products is improved, losses are minimized, production processes are optimized and costs associated with running a business are reduced. The Kaizen philosophy can be used to solve any problem and issue related to work in the organization. Its main value is to strive for the continuous company’s development through small ideas, which incrementally cause continuous improvement of the company. The paper presents how the functioning of the Kaizen philosophy in a company affects the initiatives of employees, which directly affect the optimization of processes. The presented research results show how innovative solutions consisting in limiting the use of masking tapes influence the improvement of product assembly process.
EN
Lean Management is currently one of the best-known and is the most widely used management concepts in production enterprises. Lean creates such a culture of work in an organization that makes all participants in the organization interested in raising the level of quality, reducing costs and delivery time. However, there is no information about the influence of lean tools on the level of safety in production organizations. The paper presents the influence of five lean tools on the safety level by the example of metal manufacturing organization. The number of potentially dangerous situations and the number of accidents were taken as the measure of safety level. The obtained results indicates that the most important for the safety level is 5S, TPM while Kaizen, Poka-Yoka and VSM are smaller. The paper aims to broaden the knowledge about the dependence of the use of lean tools on the level of occupational safety.
8
Content available Quality of life improvement in Kaizen aspect
EN
The aim of the research is to analyze the quality of life improvement (Kaizen) in the running aspect in Poland. Until now, issues related to the running analysis of the quality life in terms were not the subject of broader, comprehensive scientific considerations. The research was taken in 2019 year and covered a group of 396 runners. The respondents are women posing 67,9% and men posing 32,1% residing in different areas of Poland. The research was based on a questionnaire (CAWI - Computer Assisted Web Interview). Although for most respondents the result is not the most important, they try to improve their running attitude and time. Runners use different ways to be motivated to work on themselves. An example of motivators can be a medal, obtained at the finish line or sharing success with participation in competition on social networks (Facebook).
9
Content available remote Zarządzanie procesem modernizacji sieci wodociągowej w ujęciu Kaizen
PL
Niniejszy artykuł opisuje przebieg przedsięwzięcia modernizacyjnego sieci wodociągowej przeprowadzone przez GPW SA w Katowicach we współpracy z Dąbrowskimi Wodociągami w czerwcu 2018 r. z uwzględnieniem zarządzania procesem modernizacji w ujęciu koncepcji Kaizen. Proces obejmował przebudowę systemu hydraulicznego zasilania i odbioru wody ze zbiorników terenowych w Łośniu. Istotnym wyzwaniem było wybudowanie obejścia sieci wraz ze zmianą kierunku zasilania dla kilku dzielnic miasta Dąbrowa Górnicza przy zapewnieniu odbiorcom nieprzerwanych dostaw wody niepogorszonej jakości. Do zarządzania tym procesem powołano Sztab Koordynacyjny, Zespół Projektowy oraz Grupy Robocze z udziałem pracowników obu przedsiębiorstw. Wypracowano i wdrożono innowacyjne rozwiązanie polegające na zatłaczaniu wody z beczkowozów do hydrantów. Skuteczność i przydatność tego rozwiązania została potwierdzona empirycznie. Opracowanie harmonogramu prac z uwzględnieniem wieloaspektowego spektrum przewidywanych zagrożeń pozwala na podejmowanie trafniejszych decyzji zarządczych w trakcie procesu. Ścisła współpraca menadżerów różnych przedsiębiorstw uczestniczących w modernizacji sieci, wymiana informacji i wypracowywanie rozwiązań w porozumieniu zwiększa wzajemne zaufanie.
EN
This article describes the course of the water supply network modernization project carried out by GPW SA in Katowice in cooperation with Dąbrowskie Wodociągi in June 2018, including the management of the modernization process in terms of the Kaizen concept. The process involved the reconstruction of a hydraulic system for supplying and collecting water from field reservoirs in Łosień. An important challenge was to build a network bypass with a change in the supply direction for several districts of the city of Dąbrowa Górnicza while ensuring uninterrupted supply of unimpaired quality water. The Coordination Staff, Project Team and Working Groups with employees of both companies were appointed to manage this process. An innovative solution based on injecting water from water barrels into hydrants has been developed and implemented. The effectiveness and usefulness of this solution has been confirmed. Developing a work schedule taking into account the multi-faceted spectrum of anticipated threats allows making better management decisions during the process. Close cooperation of managers of enterprises participating in network modernization, exchange of information and development of solutions in agreement increases mutual trust.
PL
W artykule jest przedstawiona praca zespołu Kaizen, który analizuje problemy związane z kompletowaniem wyrobów. Opisano logistykę wyjściową i japońską filozofię pracy Kaizen. Następnie przybliżono obiekt badań – spółkę Malow w Suwałkach. Wzięto pod uwagę praktyczny aspekt zarządzania z wykorzystaniem Kaizen. Przybliżono diagnozowanie problemów, które są przyczyną marnotrawstwa. Przedstawiono również rozwiązania zaproponowane przez zespół Kaizen.
EN
Summary: The article presents the work of Kaizen Team, which analyses problems connected with completion of products. The output logistics and the Japanese philosophy of work – Kaizen were described. Then the object of research, Malow Company in Suwałki, was introduced. The practical aspect of management with the use of Kaizen was taken into account. Diagnosing problems, which are the cause of waste, was introduced. Also solutions proposed by Kaizen Team were presented.
12
Content available remote Application of spaghetti chart for production process streamlining. Case study
EN
Purpose: Improvement measures are taken unceasingly in organizations in order to optimize the obtained results in each sphere of a company’s functioning. This article presents the results of an improvement process conducted for a welding operation in the given production process. Design/methodology/approach: Taking advantage of the Kaizen approach, the article describes the results of this process and its visualization, which has been conducted with the help of a Spaghetti Chart tool. Findings: Initially, it has demonstrated that the analysis of real pathways of product value creation at the given worksite through application of the mapped-out changes brings about measurable effects. The applied worksite reorganization allowed for a limitation of an employee’s excessive movements at the worksite. In order to conduct a benchmark – both states “before” and “after” the introduction of improvement changes have been juxtaposed. Research limitations/implications: The presented analysis has a temporally and spatially limited dimension - this simultaneously being an impulse to extend research in the future. While conducting an analysis of an operator’s work, the problem must be dealt with in a broad perspective - we conduced type case study, so this is the limitation. Practical implications: The conducted analysis has taken place in real organizational conditions, using the example of a functioning worksite. Working with the “continuous improvement” approach, the instruments for development have been initiated in all spheres and levels of the given organization. Line employees have been motivated by the management to carry out single modernizations at the given worksite, which has influenced their own development. This in turn has stimulated their conscious need for active participation in the process of change. Originality/value: The conducted analysis has taken place in real organizational conditions, using the example of a functioning worksite.
13
Content available Zastosowanie narzędzi Lean w administracji
PL
Celem pracy jest przedstawienie możliwości wykorzystania wybranych instrumentów Lean i Kaizen w celu doskonalenia jakości na przykładzie organizacji pracy Gdyńskiego Centrum Wspierania Przedsiębiorczości (GCWP). W ramach przeprowadzonych badań przedstawiono szereg rozwiązań, które korzystnie wpływają na organizację i funkcjonowanie usług administracyjno-biurowych.
EN
The aim of the article is to present the possibilities of chosen Lean and Kaizen tools for improving quality by an example of work organization of Gdynia Entrepreneurship Support Centre. Within conducted studies there is a number of solutions presented which influence benefitially on organization and functioning of administrative-office services.
14
Content available Production line with embedded Lean approach
EN
The paper describes the course of the process of starting up a new assembly line with embedded Lean Management approach in one of production companies in Wroclaw. There were documented the processes of implementing and maintaining the manufacturing and logistics solutions as well as organizational and behavioral solutions that provide the basis for the new system. Then the results of the improvements to be implemented were analyzed in relation to the area functioning in accordance with the old system within the same production hall. The issue of disturbances in the system approach in connection with the introduction of changes was discussed only for a single process.
PL
Publikacja stanowi wprowadzenie do zagadnień zespołowego doskonalenia przy wykorzystaniu koncepcji Kaizen. Treścią artykułu są rozwiązania organizacyjne stosowane w przedsiębiorstwach. Publikacja powstała na podstawie literatury przedmiotu. Opisane w publikacjach doświadczenia przedsiębiorstw w Polsce stały się podstawą do opracowania struktury organizacyjnej Kaizen.
EN
The publication provides an introduction to the issues of collaborative improvement using the concept of Kaizen. The article concentrates on organizational solutions used in enterprises. The publication was based on the literature. The experience of companies in Poland, as described in the article, has become the basis for the presentation of Kaizen organizational structure.
PL
Celami artykułu są przegląd literatury dotyczącej organizacji uczącej się oraz analiza przydatności metody Kazein, która stanowi niskobudżetowe podejście do rozwiązywania problemów w organizacjach bądź doskonalenie już istniejących rozwiązań oraz ciągłego doskonalenia organizacji uczących się.
PL
Czy możliwe jest podniesienie wydajności, bezpieczeństwa, jakości, ograniczanie kosztów, skrócenie czasu produkcji bez wielomiesięcznych faz planowania, prób i analiz, niekończących się spotkań i prezentacji? Czy takie zmiany mogą być trwałe? Czy potrzebni nam są do tego eksperci? Japońska koncepcja Lean Manufacturing zakłada, że kluczowe jest rozwiązywanie problemów u źródeł i przy wykorzystaniu potencjału intelektualnego pracownikow.
EN
Invalid organisation of the production environment in an enterprise is the cause of many disruptions during the implementation of production processes. Lean Management is aimed at improving processes and eliminating interference in accordance with the Kaizen principle. A significant element of management constantly analyses and measures the improved results. The article presents the results of the literature research from the scope of observation methods and measuring the effects of the use of Lean Management instruments in manufacturing companies.
PL
Artykuł przedstawia rozwój podejść do rozwiązywania problemów w przemyśle opartych na metodzie naukowej. Rozwój systemów produkcyjnych w kierunku produkcji masowej oraz zmieniające się wymagania klienta zmienił traktowanie problemów jakościowych – uprzednio klasyfikowanych jako techniczne teraz stały się czynnikiem ekonomicznym wpływającym na wynik finansowy firmy. W związku z powyższym techniki rozwiązywania problemów musiały się również zmieniać.
EN
In the article presented development of problem solving approaches used in industry based on the scientific method. Growth of production systems into direction of mass production and changing over time customer requirements has modified defining quality related problems – formerly classified as technical, nowadays they have become economic influential factor affecting business results of any organization. Consequently, problem solving techniques had to evolve, too.
20
EN
The purpose of this article is to show the essence of Lean Management, management practices applied by companies, and the possibility for this method to be used to further improve management in an organisation. This article uses a review of existing literature, studies and reports relating to management.
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