Implementing Kaizen through a Lean RACE Model: A Case Study

Abstract

In this case study, we conducted a Kaizen implementation to eliminate waste in a quick shipping area of a manufacturing facility. Based on Toyota’s seven types of waste, specific wastes in the system are identified, and the improvement opportunities are specified. The lean RACE (Reduce, Accelerate, Consolidate, Enhance) model is then implemented to identify improvement targets in four directions: Reduce non-value-added activities to decrease interruption in the flow, Accelerate value-added activities to improve throughput and lead time, Consolidate value-added processes into fewer steps in order to shorten the value stream, and Enhance the value added through the processes to improve customer satisfaction and employee welfare such as the ergonomics of work and safer work environment. Based on the collected data, a numerical study is conducted through simulation modeling to verify the benefits of the Kaizen plan. The use of the RACE model, in this case, has projected results of reduction in transportation waste, less handling of work in process, and less waiting which leads to reduction in cycle time and increased throughput.