Analysis of critical Success factors of Gemba Kaizen in Lean Manufacturing within SA Industries.

Gemba Kaizen is used successfully by manufacturing organizations that supply Toyota South Africa (TSAM) with finished auto part. The paper seeks to establish how TSAM and its suppliers have used this Kaizen tool. The principle has been used in four stages namely going to Gemba where the manager physically goes to the production line floor. At the manufacturing floor the manager checks the whole process (machines, materials, tools, rejects), in order to identify for Muda and rejects. When the waste is identified, a temporary measure to stop the waste is quickly devised and installed to allow production to continue whilst a team of engineers is analysing ways of removing the root cause. When the solution is obtained they implement it and standardize the process establishing Standard Operating Procedures (SOPs). Gemba reduces the lead-time, rejects, and Muda in the production line whilst improving quality. [ABSTRACT FROM AUTHOR]