Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

ACKNOWLEDGEMENTS

Above all. I would like to give glory and honor to God for helping me in everything and who is
ground for my strength. Then, I would like to express my deepest appreciation to Tarcha TVET
College Deans and Trainers, Administration workers, kaizen focal person and sample employees
who contributed to the result of this study by making information easily available.

My sincere appreciation and thanks also goes to Ato Ephrem Ayisa (College Dean), Ato Bahiru
Bekalo(College Vice Dean) and especially my beloved wife W/ro Zelalem Haile who provided
me with financial and moral support.

At last, but not least, my heartfelt thanks go to all my friends whose wishes were great for the
success of this study.

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - i-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

TABLE OF CONTENTS

Contents Page

Acknowledgements----------------------------------------------------------------------------------i

List of Tables-----------------------------------------------------------------------------------------vi

List of Figures---------------------------------------------------------------------------------------vii

Abbreviations---------------------------------------------------------------------------------------viii

Abstract-----------------------------------------------------------------------------------------------ix

CHAPTER ONE

1. INTRODUCTION----------------------------------------------------------------------------------------1

1.1 Background of the Study---------------------------------------------------------------------------------

1

1.2 Statement of the Problem--------------------------------------------------------------------------------4

1.3 Research Questions---------------------------------------------------------------------------------------5

1.4 Objectives of the Study----------------------------------------------------------------------------------5

1.4.1 General Objective------------------------------------------------------------------------------------5

1.4.2 Specific Objectives-----------------------------------------------------------------------------------5

1.5 Significance of the Study--------------------------------------------------------------------------------6

1.6 Delimitation of the Study--------------------------------------------------------------------------------6

1.7 Limitation of the Study-----------------------------------------------------------------------------------

6

CHAPTER TWO

2. REVIEW OF RELATED LITERATURE-----------------------------------------------------------7

2.1 Historical Overview & Definitions of Kaizen--------------------------------------------------------7

2.2 The Dissemination of Kaizen in Ethiopia-------------------------------------------------------------9

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - ii-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

2.3 The Pillars of Kaizen------------------------------------------------------------------------------------

10

2.3.1 Kaizen as a Philosophy----------------------------------------------------------------------------11

2.3.2 Major Kaizen Systems----------------------------------------------------------------------------11

2.3.2.1 Total Quality Control/ Total Quality Management---------------------------------------11

2.3.2.2 Total Productive Maintenance---------------------------------------------------------------12

2.3.3 Kaizen Tools-----------------------------------------------------------------------------------------

13

2.4 Kaizen and Management-------------------------------------------------------------------------------15

2.4.1 Role of Top Management--------------------------------------------------------------------------16

2.4.2 Role of Middle Management ---------------------------------------------------------------------16

2.4.3 Role of Supervisors---------------------------------------------------------------------------------16

2.4.4 Role of Employees----------------------------------------------------------------------------------16

2.5 The Concept of Levels of Kaizen---------------------------------------------------------------------16

2.5.1 Management Oriented Kaizen--------------------------------------------------------------------16

2.5.2 Group Oriented Kaizen----------------------------------------------------------------------------17

2.6 Principles of Kaizen-------------------------------------------------------------------------------------18

2.7 Concept of Gemba Kaizen-----------------------------------------------------------------------------19

2.8 The Relationships between Kaizen Implementation and Reward & Recognition--------------20

2.9 The Role of Employees in the Process of Kaizen Implementation-------------------------------20

2.10 Waste (Muda) Elimination---------------------------------------------------------------------------21

2.10.1 Muda of Overproduction-------------------------------------------------------------------------21

2.10.2 Muda of Inventory---------------------------------------------------------------------------------21

2.10.3 Muda of Repair or Rejects (defects) ------------------------------------------------------------22

2.10.4 Muda of Motion------------------------------------------------------------------------------------22

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - iii-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

2.10.5 Muda of Processing--------------------------------------------------------------------------------22

2.10.6 Muda of Waiting-----------------------------------------------------------------------------------22

2.10.7 Muda of Transportation---------------------------------------------------------------------------22

2.11 Implementation of Kaizen----------------------------------------------------------------------------22

2.12 Kaizen Outcomes--------------------------------------------------------------------------------------23

2.12.1 Technical System Outcome---------------------------------------------------------------------23

2.12.2 Social System Outcome-------------------------------------------------------------------------24

CHAPTER THREE

3. RESEARCH DESIGN AND METHODOLOGY-------------------------------------------------25

3.1 Research Design-----------------------------------------------------------------------------------------25

3.2 Source of Data and Target Population----------------------------------------------------------------25

3.3 Sample Size and Sampling Techniques--------------------------------------------------------------25

3.4 Data Collection Instruments---------------------------------------------------------------------------26

3.4.1 Questionnaire----------------------------------------------------------------------------------------26

3.4.2 Interview---------------------------------------------------------------------------------------------27

3.4.3 Document Analysis---------------------------------------------------------------------------------27

3.4.4 Observation Checklist------------------------------------------------------------------------------27

3.5 Data Collection Procedures----------------------------------------------------------------------------27

3.6 Methods of Data Analysis and Interpretation-------------------------------------------------------27

CHAPTER FOUR

4. PRESENTATION, ANALYSIS & INTERPRETATION OF DATA-------------------------29

4.1 Background of the Respondents-----------------------------------------------------------------------29

4.2 Implementation of Kaizen Program------------------------------------------------------------------32

4.3 Kaizen Program Implementation and Related Challenges-----------------------------------------36

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - iv-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

CHAPTER FIVE

5. SUMMARY, ACTIONPLAN, IMPLEMENTATION, EVALUATION &

RECOMMENDATIONS-------------------------------------------------------------------------------- 38

5.1 Major Findings---------------------------------------------------------------------------------------------------38

5.2 Proposal for Action---------------------------------------------------------------------------------------------39

5.3 Implementation and Strategy----------------------------------------------------------------------------------39

5.4 Action Evaluation-----------------------------------------------------------------------------------------------40

5.5 Conclusions-------------------------------------------------------------------------------------------------------40

5.6 Recommendations------------------------------------------------------------------------------------------------41

REFERENCES-----------------------------------------------------------------------------------------------------42-44

APPENDICES-----------------------------------------------------------------------------------------------------45-52

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - v-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

LIST OF TABLES

Table Page

Table 2.1 Distribution of Respondents and Collection of Questionnaire and Interview--------------------25

Table 4.1 Items related to Employees’ Perception at workplace in implementing kaizen----------32

Table 4.2 Employee Training program--------------------------------------------------------------------33

Table 4.3 Difficulty of Kaizen in Practice----------------------------------------------------------------34

Table 4.4 Knowledge of Continuous Improvement-----------------------------------------------------34

Table 4.5 Management feedback to employees regarding Kaizen program implementation------35

Table 4.6 Rating Kaizen Program Implementation and related Challenges--------------------------36

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - vi-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

LIST OF FIGURES

Figures Page

Figure 1.1 Some Basic Kaizen Techniques--------------------------------------------------------------13

Figure 2.1 The Plan-Do-Check- Act (PDCA) Cycle----------------------------------------------------17

Figure 4.1 Distribution of respondents by sex-----------------------------------------------------------29

Figure 4.2 Distribution of Respondents by age----------------------------------------------------------30

Figure 4.3 Distributions of Respondents by Qualification---------------------------------------------30

Figure 4.4 Distribution of Respondents by Experience-------------------------------------------------31

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - vii-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

ABBREVIATIONS

BSC Balance Score Card

CI Continuous Improvement

EKI Ethiopia Kaizen Institute

IPD Initiative for Policy Dialogue

JICA Japanese International and Cooperation Agency

JIT Just In Time

JPC Japan Production Center

JUSE Union of Japanese Scientists & Engineers

MOI Ministry of Industry

PDCA Plan-Do-Check-Act

PQCDMSEG Productivity, Quality, Cost, Delivery time, Moral, Safety, Environment & Gender equality

QCC Quality Control Cycle

5S Five (Sort, Set in Order, Shine, Standardize, and Sustain)

SNNPR South, Nations, Nationalities & People Region

TIISO Testing, Institutionalization, Implementation, Sustain, & Ownership

TPM Total Production Management

TPS Total Productive System

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - viii-

 Action Research ፡ IMPROVING EMPLOYEES’ PERCEPTION TOWARS THE IMPLEMENTATION OF KAIZEN PROGRAM

TQC Total Quality Control

TQM Total Quality Management

WWII The Second World War

ABSTRACT

The purpose of the study was to improve employees’ perception towards the implementation of
Kaizen programs at Tarcha Industrial College Dawuro Zone, SNNPR. To conduct this study
descriptive research design was employed. A simple random sampling technique was used to
select employees and purposive sampling technique was selected for college Deans and kaizen
focal person. Questionnaire, interview, observation checklist, and document analysis were data
collection tools employed in this study. The data gathered through questionnaire were analyzed
using frequency and percentage while data obtained through interview were qualitatively
narrated. The study disclosed that there were inadequate training on the concept and application
of kaizen and over all the implementation of kaizen program in the college was challenged. This
has an effect on the overall activities of kaizen sustainability and standardization. After the major
findings were identified, in order to improve the problem, action proposal was planned, it was
implemented, action was evaluated and finally, improvement in implementing kaizen program
was detected.

By: YIRGALEM AYELE (MA) TARCHA INDUSTRIAL COLLEGE: SNNPR - ix-