Track: Operations Management

Abstract

Gemba Kaizen is used succesfully in manufacturing organizations that supply Toyota South Africa (TSAM) with finished auto parts. The paper seeks to establish how TSAM and its suppliers have succesfully used the Kaizen philosophy. Gemba Kaizen is where the senior managers goes to the manufacturing floor or production line to see for themselves the whole manufacturing process. They observe the machines, manpower,  materials and  methods used in manufacturing (4Ms)  in order to identify the waste ( muda). When a Muda is identified a temporary measure to control the waste is applied whilst a team of staff and engineers is brainstorming and analysing the problem to find the root cause. When the root cause is obtained the best solution is adopted and standard operating procedures (SOPs)  set before implimenting the solution.Gemba reduces the eight waste in manufacturing.