Success Stories
Lean Production Success at KazTek
Jan
KazTek is a manufacturer of lighting products based in Almaty. The company signed a Lean Production consultancy agreement
with Lean Solutions in 2023.
Lean Solutions has implemented the following practices and trainings at KazTek:
- 5S: A system to ensure workplace organization, cleanliness, and efficiency.
- Stock A3: A planning tool to reduce stocks.
- A3 reporting: A reporting system used to identify, analyze, solve a problem, and track results.
- Video job analysis and VSM: A technique used to analyze production processes and identify improvement opportunities.
- SMED and signal kanban on injection machines: Techniques used to reduce setup and preparation times for production machines.
- Before-after Kaizen: A technique used to identify improvement opportunities by comparing the before and after of a process.
- Two-bin material feeding: A method used to ensure materials are available when needed.
- Setup and activation of finished product supermarkets and kanban: A method used to ensure finished products are available when needed.
- Production planning and capacity control: Techniques used for planning production according to needs and controlling capacity.
- SOP (Standard Operating Procedure): Documents used to standardize business processes.
- Autonomous maintenance and planned maintenance: Techniques used to increase the efficiency and availability of machines and equipment.
- VSM Study in Metal Welding Workshop: A study conducted to analyze the production processes of the metal welding workshop and identify improvement opportunities.
- Activation of the Asakai line management system: A system used to increase the efficiency of production lines.
- OTIF calculation training and implementation: A metric used to measure shipment performance.
As a result of these practices and trainings at KazTek, the following outcomes were achieved:
- Stocks were reduced by 70%.
- Production performance increased by 50%.
- Labor costs decreased by 30%.
- OTIF rate increased to 80%.
- Workplace safety and employee satisfaction increased.
KazTek’s Lean Production journey has helped the company achieve
operational excellence. This success demonstrates that Lean Production is a
powerful tool that helps businesses reduce costs, increase efficiency,
and improve competitiveness.
Example of Improvement
An example of improvement at KazTek is the establishment and improvement of
the projector assembly cell. As a result of establishing this cell, assembly time was reduced by 50%
and productivity increased by 100%.
The following steps were taken to implement this improvement:
- The location and design of the cell were determined.
- Necessary equipment and materials were provided.
- Production processes were analyzed, and improvement opportunities were identified.
- Kaizen activities were conducted.
After the establishment of the cell, assemblers were able to work more efficiently.
Materials and equipment were placed closer, reducing operators’
walking distances. Production processes were simplified, and unnecessary
steps were eliminated.
As a result of this improvement, the projector assembly cell became
a significant production center for projection lamps.
Conclusion
KazTek’s Lean Production journey has helped the company achieve
operational excellence. This success demonstrates that Lean Production is a
powerful tool that helps businesses reduce costs, increase efficiency,
and improve competitiveness.
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