Assessing the Effect of Kaizen Practices on Operational Efficiency: A Case Study of a Steel Manufacturing Company in Zambia

This study evaluates the effect of Kaizen practices on operational efficiency at a steel manufacturing company in Zambia, employing a mixed-method research design. Data were collected through semi-structured interviews, structured questionnaires, and direct observations. Questionnaires were distributed to 317 employees, achieving an 83.3% response rate, and interviews were conducted with 8 key participants. Quantitative data were analyzed using descriptive and inferential statistics, including correlation, regression analyses, t-tests, and ANOVA, while qualitative data underwent thematic analysis. Results indicate that 5S, Total Productive Maintenance (TPM), and Total Quality Management (TQM) significantly improved production cycle times, defect rates, equipment downtime, and costs. Regression analysis revealed that TQM and TPM contributed 30% to efficiency gains, followed by 5S (25%) and 5W1H (20%). t-tests confirmed statistically significant improvements in key metrics post-Kaizen implementation, and ANOVA highlighted inter-departmental variations in adoption rates. Barriers such as inadequate resources, insufficient training, and resistance to change were identified. Recommendations include strengthening training programs, enhancing leadership commitment, and allocating sufficient resources. Prospects for future research include exploring Kaizen's application in diverse industries, examining its long-term effects, and integrating advanced technologies. This study underscores the transformative potential of Kaizen practices and provides actionable insights for enhancing operational efficiency in manufacturing contexts.