Implementation of Kaizen event for continuous improvement in the production process of a bikes factory in the Manaus Free Trade Zone

Abstract

The general objective is to demonstrate, through a case study, the implementation of a Kaizen event based on the Lean manufacturing philosophy, in a bicycle factory located in the Manaus Free Trade Zone. In addition to the case study, bibliographical, explanatory research was carried out, of a quantitative nature and supported by participant observation. It focused on the pre-assembly process of one of the bicycle models, which required improvements in terms of its operationalization. A time and movement study was carried out together with the Yamazumi Chart, with a view to identifying activities that did not add value at the 3 pre-assembly stations. In the field research, work benches were detected in a precarious state, as well as poorly allocated materials and waste from handling. With the implementation of improvements, the pre-assembly area was completely reorganized and this generated productivity gains, which were identified through a new chronoanalysis and Yamazumi Chart. The Kaizen event represents an opportunity to reduce costs followed by increasing the level of quality and productivity in organizations and optimizing production.