Reduction of Terminal Rejections and Failure Cost through Kaizen at Shop Floor of a Wire Harness Manufacturing Company

In the cutthroat market, demand for higher-quality products is currently the most important task in front of organization and management looks for better effectiveness. In manufacturing units, high cost, declining profit boundaries, discrepancy of quality of products, and delivery of such products in the competitive market are the factors those have encouraged many organizations to focus on ways to increase the involvement of employees to improve quality and productivity. Kaizen is one of the employee contribution methods intended to bring together all level of workforce in an organization for setting principles of excellence and achieving better consequences. In this paper, it is tried to analyze the performance of Kaizen in a wire harness manufacturing unit which is considered for the study, and the paper presents a case study of the selected company to reduce rejections due to high contact gap in terminal that further confides decrement in failure cost.