Implementation of Kaizen in Various Industries: A Systematic Literature Review
DOI:
https://doi.org/10.20961/performa.v24i2.2746Keywords:
Kaizen, Management Tools, Manufacturing, Productivity, Services, WasteAbstract
Kaizen is a strategic approach that focuses on continuous improvement to increase an organization's efficiency, quality, and productivity. This article explores the implementation of Kaizen in various sectors through a literature review of 45 articles published between 1996 and 2024. This research aims to identify the application, benefits, and challenges of Kaizen in various industries, both manufacturing and services. The results of the review show that Kaizen has been successfully applied in various sectors, especially manufacturing (31 articles), with a focus on methods such as 5S, Kanban, and the PDCA cycle to reduce waste and increase productivity. Additionally, the application of Kaizen has expanded to non-manufacturing sectors, such as healthcare, education, and the public sector, where this approach contributes to operational efficiency and improved services. However, challenges such as resistance to change, limited resources, and lack of management support often become obstacles to implementation. This study provides recommendations for the development of a more strategic and adaptive Kaizen approach in the modern business environment as a relevant and effective management tool in various industrial contexts.
References
Agmoni, E. (2015). The Role of Kaizen in Creating Radical Performance Results in a Logistics Service Provider, Logforum, 12(3), 225–245. https://doi.org/10.17270/J.LOG.2016.3.4
Alarcón, R. B., Cristina, L., & Santos, V. D. L. (2024). Implementation of Machine Learning in the Categorization of Improvement Areas for Kaizen Submissions, European Journal of Electrical Engineering and Computer Science, 8(5), 12–17. https://doi.org/10.24018/ejece.2024.8.5.648
Alvarado-Ramírez, K. M., Pumisacho-Álvaro, V. H., Miguel-Davila, J. Á., & Suárez Barraza, M. F. (2018). Kaizen, A Continuous Improvement Practice In Organizations: A Comparative Study in Companies From Mexico and Ecuador. TQM Journal, 30(4), 255–268. https://doi.org/10.1108/TQM-07-2017-0085
Androniceanu, A., Enache, I. C., Valter, E. N., & Raduica, F. F. (2023). Increasing Energy Efficiency Based on the Kaizen Approach. Energies, 16(4). https://doi.org/10.3390/en16041930
Baril, C., Gascon, V., Miller, J., & Côté, N. (2016). Use of a discrete-event simulation in a Kaizen event: A case study in healthcare. European Journal of Operational Research, 249(1), 327–339. https://doi.org/10.1016/j.ejor.2015.08.036
Bellgran, M., Kurdve, M., & Hanna, R. (2019). Cost driven green kaizen in pharmaceutical production – Creating positive engagement for environmental improvements. Procedia CIRP, 81(March), 1219–1224. https://doi.org/10.1016/j.procir.2019.03.297
Bortolotti, T., Boscari, S., Danese, P., Medina Suni, H. A., Rich, N., & Romano, P. (2018). The social benefits of kaizen initiatives in healthcare: an empirical study. International Journal of Operations and Production Management, 38(2), 554–578. https://doi.org/10.1108/IJOPM-02-2017-0085
Cardoso, W., Bassi, E., Bertosse, J. F., Saes, R. M., & Achcar, J. A. (2018). The implementation and use of the “5s” and Kaizen program for the management of sewing offices of a middle family company. Independent Journal of Management & Production, 9(3), 767–784. https://doi.org/10.14807/ijmp.v9i3.726
Chikwendu, O. C., Ifeyinwa, O. F., Igbokwe, N., O., Chidiebube, I. N., & Utochukwu, O. E. (2021). The Implementation of Kaizen Manufacturing Technique : A Case of a Tissue Manufacturing Company
Dandin, S. V, & Mench, R. G. (2015). Development and implementation of Kaizen activities in an Automobile manufacturing firm. International. Journal of Innovative Research in Advanced Engineering, 6(2), 2349–2163.
Darmawan, H., Hasibuan, S., & Hardi Purba, H. (2018). Application of Kaizen Concept with 8 Steps PDCA to Reduce in Line Defect at Pasting Process: A Case Study in Automotive Battery. International Journal of Advances in Scientific Research and Engineering, 4(8), 97–107. https://doi.org/10.31695/ijasre.2018.32800
Desta, A., Asgedom, H. B., Gebresas, A., & Asheber, M. (2014). Dominican Scholar Dominican Scholar Collected Faculty and Staff Scholarship Faculty and Staff Scholarship Analysis of Kaizen Implementation in Northern Ethiopia’s Analysis of Kaizen Implementation in Northern Ethiopia’s Manufacturing Industries. www.ijbcnet.com
Fatkhurrohman, A., & Subawa. (2016). Penerapan Kaizen dalam Meningkatkan Efisiensi dan Kualitas Produk pada Bagian Banbury PT. Bridgestone Tire Indonesia. Jurnal Administrasi Kantor, 4(1), 14–31.
Gasper, L., & Beny Mwenda. (2023). Quantitative analysis of Kaizen philosophy on productivity improvement. International Journal of Research in Business and Social Science, 12(3), 557–562. https://doi.org/10.20525/ijrbs.v12i3.2455
Goyal, A., Agrawal, R., Chokhani, R. K., & Saha, C. (2019). Waste reduction through Kaizen approach: A case study of a company in India. Waste Management and Research, 37(1), 102–107.https://doi.org/10.1177/0734242X18796205
Gunawan, K., & Nurbani, S. N. (2023). Penerapan Kaizen Costing Menggunakan Metode Pdca Untuk Memaksimalkan Cost Reduction Di Pt Ibara Lioho Indonesia. Prosiding Seminar Sosial Politik, Bisnis, Akuntansi dan Teknik (SoBAT) 1, 315–326.
Gupta, S., & Jain, S. K. (2014). The 5S and kaizen concept for overall improvement of the organisation: a case study. International Journal of Lean Enterprise Research, 1(1), 22. https://doi.org/10.1504/ijler.2014.062280
Hartono, H., & Fatkhurozi, F. (2021). Penerapan Kaizen Untuk Mengurangi Loss Time Dalam Peningkatan Produktivitas Mesin Infrared Welding (Studi Kasus Pt. Mitsuba Indonesia). Journal Industrial Manufacturing, 6(1), 01. https://doi.org/10.31000/jim.v6i1.4114
Ihsan, M., Hasanah, R., & Purba, H. H. (2019). Fanuc CNC machine damage analysis using the PDCA cycle and Kaizen implementation effort in increasing skill up operator performance in PT YPMI. Independent Journal of Management & Production, 10(1), 259–280. https://doi.org/10.14807/ijmp.v10i1.590
Ioana, A. D., Maria, E. D., & Cristina, V. (2020). Case study regarding the implementation of one-piece flow line in automotive company. Procedia Manufacturing, 46, 244–248. https://doi.org/10.1016/j.promfg.2020.03.036
Jacobson, G. H., McCoin, N. S., Lescallette, R., Russ, S., & Slovis, C. M. (2009). Kaizen: A method of process improvement in the emergency department. Academic Emergency Medicine, 16(12), 1341–1349. https://doi.org/10.1111/j.1553-2712.2009.00580.x
Kumar, R. (2019). Kaizen a tool for continuous quality improvement in Indian manufacturing organization. International Journal of Mathematical, Engineering and Management Sciences, 4(2), 452–459. https://doi.org/10.33889/ijmems.2019.4.2-037
Lyu, J. (1996). Applying kaizen and automation to process reengineering. Journal of Manufacturing Systems, 15(2), 125–132. https://doi.org/10.1016/0278-6125(96)82337-5
Mano, Y., Akoten, J., Yoshino, Y., & Sonobe, T. (2014). Teaching KAIZEN to small business owners: An experiment in a metalworking cluster in Nairobi. Journal of the Japanese and International Economies, 33, 25–42. https://doi.org/10.1016/j.jjie.2013.10.008
Markova, N. A., & Markov, D. A. (2018). Practices of Kaizen Implementation at the Industrial Enterprise. Journal of the Ural State University of Economics, 19(5). https://doi.org/10.29141/2073-1019-2018-19-5-10
Mazzocato, P., Stenfors-Hayes, T., Schwarz, U. V. T., Hasson, H., & Nyström, M. E. (2016). Kaizen practice in healthcare: A qualitative analysis of hospital employees’ suggestions for improvement. BMJ Open, 6(7), 1–8. https://doi.org/10.1136/bmjopen-2016-012256
Mitreva, E., Todorova, P., & Kicara, D. (2024). Application of Kaizen Philosophy in Business Process Improvement in the Automotive Industry. SAR Journal - Science and Research, 7(2), 113–119. https://doi.org/10.18421/sar72-07
Okada, N., Umemura, Y., Shi, S., Inoue, S., Honda, S., Matsuzawa, Y., Hirano, Y., Kikuyama, A., Yamakawa, M., Gyobu, T., Hosomi, N., Minami, K., Morita, N., Watanabe, A., Yamasaki, H., Fukaguchi, K., Maeyama, H., Ito, K., Okamoto, K., … Fujimi, S. (2024). “KAIZEN” method realizing implementation of deep-learning models for COVID-19 CT diagnosis in real world hospitals. Scientific Reports, 14(1), 1–15. https://doi.org/10.1038/s41598-024-52135-y
Okpala, C., Nwamekwe, C. O., Ezeanyim, O. C., Chikwendu, O. C., Chiedu, O., & Onyeka, N. C. (2024). The Implementation of Kaizen Principles in Manufacturing Processes: A Pathway to Continuous Improvement. International Journal of Engineering Inventions, 13(7), 116–124.
Prasetyo, Y. M. (2023). Pengaruh Gaya Kepemimpinan, Budaya Kaizen, dan Kesejahteraan Terhadap Kepuasan Kerja. JIBEMA: Jurnal Ilmu Bisnis, Ekonomi, Manajemen, Dan Akuntansi, 1(1), 77–86. https://doi.org/10.62421/jibema.v1i1.8
Prashanth, K. C., & Veena, M. (2022). Kaizen (Continuous Improvement) for employee productivity.
Rachmatullah, R., Kasih, T. P., & Purba, H. H. (2015). The Effect of 5K2S Implementation to the Opportunities of Increasing Productivity and Workplace Improvement in PT. Andesen Jaya Plastik. ComTech: Computer, Mathematics and Engineering Applications, 6(4), 590. https://doi.org/10.21512/comtech.v6i4.2197
Radharamanan, R., Godoy, L. P., & Watanabe, K. I. (1996). Quality and productivity improvement in a custom-made furniture industry using Kaizen. Computers and Industrial Engineering, 31(1–2), 471–474. https://doi.org/10.1016/0360-8352(96)00177-5
Rahmanian, F., & Rahmatinejad, Z. (2013). Impact of Kaizen implementation on performance of manufacturing companies ’ staff. European Online Journal of Natural and Social Sciences, 2(3), 1094–1103.
Rahmanto, W. Y., & Soediantono, D. (2022). Studi Kualitatif Dampak Kaizen Terhadap Keunggulan Kompetitif Perusahaan Industri Pertahanan. Journal of Industrial Engineering & Management Research, 3(4), 41–49. https://jiemar.org/index.php/jiemar/article/view/298
Rewers, P., Trojanowska, J., Chabowski, P., & Żywicki, K. (2016). Impact of Kaizen Solutions on Production Efficiency. Modern Management Review, https://doi.org/10.7862/rz.2016.mmr.53
Rouf, M. A., Debnath, S. C., Haque, M. E., Chowdhury, Z. M. R., Hasan, D. M. M., Zannat, T., & Rabby, M. F. (2017). Quality of hospital services in 5S-KAIZEN-TQM implemented secondary level hospital: a cross-sectional study. Asian Journal of Medical and Biological Research, 3(3), 335–340. https://doi.org/10.3329/ajmbr.v3i3.34522
Sahri, N. A., & Novita, N. (2019). Kaizen Costing sebagai Perbaikan Berkelanjutan untuk Meningkatkan Keunggulan Bersaing pada E-Commerce. Jurnal Kajian Akuntansi, 3(1), 18. https://doi.org/10.33603/jka.v3i1.2136
Shojaei, M., Ahmadi, A., & Shojaei, P. (2019). Implementation productivity management cycle with operational Kaizen approach to improve production performance (Case study: Pars Khodro company). International Journal for Quality Research, 13(2), 349–359. https://doi.org/10.24874/IJQR13.02-07
Siswanto, Y., & Wijayanto, H. L. (2023). Analisa Implementasi Kaizen Di Laboratorium Teknik Perawatan Mesin Politeknik Industri Logam Morowali. Jurnal Inovasi Penelitian, 3(9), 7479–7488.
Taib, M. Y., Ismail, A. R., & Yusoff, A. R. (2010). a Case Study of Kaizen Implementation in Smi. National Conference in Mechanical Engineering Research and Postgraduate Studies, 3-4 December, 374–392.
Titu, M. A., Oprean, C., & Grecu, D. (2010). Applying the KAIZEN method and the 5S technique in the activity of post-sale services in the KNOWLEDGE-based organization. Proceedings of the International MultiConference of Engineers and Computer Scientists 2010, IMECS 2010, III, 1863–1867.
Topuz, C., & Arasan, Z. (2013). Kaizen-educational: An Awareness-raising and Motivational-enhancement Group Counseling Model. Procedia - Social and Behavioral Sciences, 84, 1356–1360. https://doi.org/10.1016/j.sbspro.2013.06.756
Umeda, Y., Ota, J., Shirafuji, S., Kojima, F., Saito, M., Matsuzawa, H., & Sukekawa, T. (2020). Exercise of digital kaizen activities based on “digital triplet” concept. Procedia Manufacturing, 45, 325–330. https://doi.org/10.1016/j.promfg.2020.04.025
Wicaksono, P. A., & Rozaq, R. (2020). Applying Kaizen in Quality for Reducing Dent Defect per Unit. IOP Conference Series: Materials Science and Engineering, 722(1). https://doi.org/10.1088/1757-899X/722/1/012041
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Performa: Media Ilmiah Teknik Industri
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
