At the end of last year, the head of the IntiLED production system development department was selected for an internship program under the OJT Kaizen in Production program organized by the Ministry of Foreign Affairs of Japan. The internship included a visit to industrial enterprises in Japan, a lecture course, and workshops. The focus of the program was on the organization of the process of continuous improvement on the production of Panasonic Corporation, Yamatoya Company, FANCL Corporation, KEIO Corporation, and TOTO Corporation. During the internship, the head of the IntiLED production system development department learned technologies and activities of Japanese enterprises, as well as discussed with foreign colleagues the kaizen philosophy and the experience of implementing the lean manufacturing system at IntiLED.
The design specificity of IntiLED binds to the immaculate organization of the production process and the highest work efficiency. The implemented system of Lean Production, an enterprise management concept based on the Kaizen philosophy, helped to achieve this. The main idea is to continuously improve processes by means of constant search for opportunities to improve and implement such improvements. The system envisages the involvement of every employee in the process of optimizing the business and the maximum customer focus.
The first steps to implement the system were made at IntiLED in 2011. In less than 9 months, thanks to the forming-up of the production process, the productivity was increased by 3 times with the same amount of personnel. From 2012 to 2014, active work was carried out to improve product quality within the framework of the Lean Production concept. In 2015, the 5S system was implemented, as a result of which the section productivity increased by 20%. The 5S system is one of the methods of Lean Production, aimed at organizing an effective working space. It provides 5 steps: sort, set in order, shine, standardize and sustain. From 2016 to 2017, the Total Productive Maintenance (TPM) system and the Single-Minute Exchange of Dies (SMED) were implemented for the SM line, which resulted in a 22% increase in the overall equipment efficiency ratio.
Today, Kaizen is an integral part of Lean Production culture, which we strive to implement and develop at IntiLED. Regular work in this direction allowed improving productivity, safety, and product quality.
The OJT Kaizen in Production program is conducted by the Government of Japan within the framework of technical assistance to Russia in promoting reforms, including the implementation of the Presidential Program for the Training of Management Personnel for National Economy Organizations of the Russian Federation. Carrying out this internship contributes to the development of Japanese-Russian trade and economic relations, as well as to the expansion of trade and investment volumes between the two countries.