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METHODOLOGYThe kaizen step is the method (refer Figure 1) to develop Kaizen projects, and followsPDCA approach. All improvement projects, despite of their nature (costs, quality,safety, ergonomics, environment, logistics, etc.) must follow specific guidelines whichare defined within kaizen step. Guidelines mean what project type, operating steps andtools to be used and way of using them.Step 1: Define Pilot AreaDefine pilot area is the first step towards ongoing with the improvement activities.Bottleneck processes are commonly defined the pilot area. In order to find thebottleneck process, the business general procedures as well as sales order processingflow is mapped starting from order enter until delivery and payments from customer. Inthe process mapping of sales order processing (Refer appendix A), step 14 which isproduction run are mapped separately in order to get real time of existing processes inproduction (appendix B). From the process mapping of the sales order processing, totallead time is 169.81 hours. Noticed, that the processes have bottleneck at productionprocess which is 60.97 hours. So, the pilot area is defined at production.
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