Challenges in the Implementation of Kaizen in Manufacturing Industries under Ethiopian Kaizen Institute

Abstract

The purpose of the study was to assess the Challenges of Kaizen Implementation in Manufacturing Industries under EKI supervision. In addition the objectives were to identify the bottlenecks in the implementation and sustainability of Kaizen activity.to examine the capacity and gaps of the Ethiopian Kaizen Institute in delivering consultancy service and follow up and to suggest possible recommendation and solutions/ for implementation and sustainability of Kaizen in the companies. To address the objectives, descriptive research design was used, primary and secondary data and also a mixed research methods (i. e. an approach of both quantitative and qualitative data collection methods) were used to collect data from industries employees and managements and EKI consultants and directors. The data gathered through questionnaire were analyzed using frequency and percentage value of the respondents. Data obtained through interview were qualitatively narrated. Kaizen implementation with in the selected companies were brought some changes in minimizing work flows and in reducing time conception but there had been challenges which came up from various sources, like gaps in customization of training material, their lack technical knowledge in training and implementation; gaps in providing resources for implementation, poor commitment, interest and support of top managements, gaps in implementing recognition and rewards in the company, poor participatory approaches of managements and employees in the company, gaps in consulting and supporting consistently, lack of practical demonstration in training and sustaining methods were used. The study disclosed that there were inadequate training on the concept and application of kaizen. This has an effect on the overall activities of kaizen implementation and sustainability. Finally, the study recommended for two parties i.e. EKI and manufacturing industries. For EKI side, the Institute consultants should conduct regular supportive monitoring and follow up consulting to the industries, the duration of the training and consultancy time which the EKI provided should be increased based on the gaps of the companies, the consultants should better have a technical skill of the companies for training and manual preparation and consultancy are recommended.