Kaizen practices and performance improvement in Zambian manufacturing companies

Abstract

There is strong evidence that Zambian manufacturing organisations are increasingly implementing Kaizen programs to help them improve productivity and enhance delivery performance. This study aims to investigate the relationship between Kaizen practices and improvement in performance in Zambian manufacturing companies. The study also sought to determine the challenges faced by manufacturing companies in implementing Kaizen practices. The study employed a cross-sectional descriptive research design with the target population being manufacturing companies in two highly industrialised regions in Zambia. Thirty-three questionnaires were distributed, and 31 companies responded. Based on the conceptual framework developed, hypotheses were formulated and tested using the ordinary least squares regression modelling approach. The results show that the 5Ss were the most popular activities implemented, while the Suggestion System was the least implemented. Implementing Kaizen practices leads to significant operations performance improvements in manufacturing companies in the form of productivity, quality, and overall equipment effectiveness. The results also show that employee attitude is the major challenge in implementing Kaizen, while management support or leadership is the last hurdle. The research provides an early understanding of the successes of the implementation of Kaizen practices in manufacturing companies in Zambia.

Keywords:

• employee attitudes
• Kaizen practices
• manufacturing companies
• performance improvement
• Zambia

PUBLIC INTEREST STATEMENT

To build an industrial nation that sees a strong and dynamic middle-income industrial nation that provides opportunities for improving well-being, there is a great need for increased productivity and quality in the products and services produced. Zambian manufacturing firms have adopted Kaizen principles to contribute to the country’s goal of being a successful middle-income nation by improving operational performance. This study investigated the relationship between Kaizen implementation and operational performance improvement in Zambian manufacturing organisations. Firstly, the value of this research was to inform management, the Kaizen Institute of Zambia, and government policymakers about the successes of the implementation of Kaizen practices in manufacturing companies in Zambia. Secondly, the value of this research was to highlight the challenges faced by manufacturing companies in Zambia in implementing Kaizen practices so that more resources could be directed at reducing these challenges so that companies can enjoy the benefits of Kaizen practices.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

The authors received no direct funding for this research.

Notes on contributors

Chanda Sichinsambwe

Chanda Sichinsambwe is a senior lecturer with over 25 years at the Copperbelt University, School of Business. His research interests include TQM, Quality Management, Lean Manufacturing, Operations Management, Process Improvement, Production Planning, and Inventory Management Optimization

Peter Lubosi Simasiku

Peter Lubosi Simasiku has over 12 years of combined industry and teaching experience. Simasiku holds an MSc in Supply Chain Management & Logistics from the University of Southampton and a BSc in Production Management from Copperbelt University. Prior to joining Copperbelt University, he worked in the Manufacturing and Brewing Industries for over 5 years in Zambia as a Team Leader, Maintenance Planner, Packing plant Superintendent, production supervisor, and packaging supervisor.

Shem Sikombe

Shem Sikombe has over 10 years of teaching, administrative and research experience at the university level. His research interest is in Sustainable Procurement, Supply Chain Management, and SME-oriented Public Procurement policies. Sikombe has an earned PhD in Supply Chain Management from Kwazulu-Natal in South Africa.

Harris Nyimbili

Harris Nyimbili has over 20 years of experience in Supply and Distribution, sourcing and procurement. His main role is to ensure the effective development of procedures and processes and monitor that they are working to ensure the safety and efficiency of the entire Supply Chain. Nyimbili holds a BSc in Production Management and an MBA, he is currently a Lecturer at the Copperbelt University, School of Business.