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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 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilarmethodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt fromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained hereinorforanyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerInternationalPublishingAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland 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 implementation. 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 validation 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 relationship 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

Description:

This book reports a literature review on kaizen, its industrial applications, critical success factors, benefits gained, journals that publish about it, main authors (research groups) and universities. Kaizen is treated in this book in three stages: planning, implementation and control. The authors