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In manufacturing, corporate growth and profitability are more challenging than ever before. The company reviewed in this study has been and is currently suffering tremendous growing pains with poor record of profitability. This paper reports learning and application of a few significant techniques to improve basic business practices in a company, which manufactures large volume, high quality optical thin film coatings. Some of the tasks involved in identifying opportunities for improving operational efficiencies included analysis of current business processes, identification of non‐value‐added activities including wastes and proposing process changes. Process mapping and kaizen “blitz” activities were utilized during analysis of key business processes within this company. The study demonstrates measurable results realized through use of process mapping tools, kaizen blitz activities, formalized and documented work instructions and work measurement tools. To ultimately be successful, a company must educate their workforce and create a fulfilling work environment for each of their employees. Worker involvement is essential and critical in today's society. Gaining the worker's trust and commitment is extremely important.
Kumar et al. (Wed,) studied this question.