Quality Improvement in Automobile Assembly Production Line by Using Kaizen

The 'part mismatch problem' is one of the general quality, problems in automobile assembly production line. Part mismatch affects the production by quality rejection, rework, down time etc. Most of the time part mismatches leads to major functional problem at the assembly section. Kaizen is a method which can control and eliminate such part mismatch problems in automobile assembly production. In this paper, the applicability of kaizen for quality improvement in the production of automobile assemblies with a case study is illustrated. By using kaizen, automobile assembly production line quality problem is solved. Case study about the bracket mismatch leads to brake hose mounting nut offset. This was the major problem of the under body assembly. Step by step kaizen procedure followed to solve the problem by data collection, ischolar_main cause analysis, selection of best solution method, corrective action, documentation and continuing improvement. Kaizen implementation for solving the problem also reflects in the improvement of quality, cost reduction, delivery to customer, morale of the employees and safety. Kaizen was found to be an effective process for improving the quality and productivity. Practical implications of Kaizen can improve the productivity by downtime reduction and quality improvement.