THIS is an interesting case of a five-year old factory with 200-plus workers, including 90 contractual workers. The newcomer factory has encountered many operational issues but its management focused on solving only costly ones. Recently, top management thought of creating a Kaizen program that requires all workers, regardless of rank and employment status to help solve all issues, regardless of its financial impact – big or small.

They hired a Kaizen consultant who created a road map, including a two-day course on waste elimination and how an army of workers would proceed under the principle of industrial democracy. It requires the voluntary, but active participation of workers in problem solving.

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