Conceptual Framework for Implementing Bottom-Up Kaizen in the Malaysian Automotive Sector

Subject Areas : manufacturing and process planning

S.K.   Kamal ¹ (Management of Technology, Malaysia-Japan International Institute of Technology, Universiti Teknologi Malaysia, Kuala Lumpur, 54000 Malaysia )
ZA   Rahim ² (Management of Technology, Malaysia-Japan International Institute of Technology, Universiti Teknologi Malaysia, Kuala Lumpur, 54000 Malaysia )
I.   Norzura ³ (Arshad Ayub Graduate Business School, Universiti Teknologi MARA, Sg. Petani 08400 Malaysia)
H   Nakanishi ⁴ (Institute of Ocean Energy, Saga University 1 Honjo-machi, Saga, 840-8502, Japan)
Hamad  Raza ⁵ (GC University Faisalabad)

Received: 2024-04-28 Accepted : 2024-06-06 Published : 2024-06-06

Keywords: Bottom-up, Kaizen, Development Design Research, Fuzzy Delphi Method, Partial Least Squares,

Abstract :

This research aimed to discern the determinants shaping the implementation of bottom-up Kaizen models in the Malaysian automotive industry, conducted in three distinct phases: needs analysis, design and development, and evaluation. The identification of model prerequisites involved utilizing two instruments. In the initial phase, a panel of 11 experts employed the Fuzzy Delphi Method (FDM) to formulate the model, relying on a 5-point Likert scale survey questionnaire for expert feedback. The second phase employed a Partial Least Square Structural Equation Model (PLS-SEM) approach to appraising the model, involving 300 employees in the automotive manufacturing sector. The outcomes from the first phase led to the creation of a model featuring eight constructs encompassing 41 items, specifically tailored for bottom-up Kaizen activities in the Malaysian automotive industry. Subsequently, the results from the second phase underscored that the bottom-up Kaizen activity model comprises seven constructs, wherein only statistically significant and positively influential factors for both direct and mediated paths were considered. This study has culminated in the formulation of a structural relationship model for Bottom-up Kaizen criteria, offering significant potential benefits and serving as a valuable reference for the Malaysian automotive industry.

References:

Alid, H., Hashime, N., Kejuruteraan, S. P.-J., & 2021, undefined. (2021). An analysis of end-of-life vehicle policy implementation in Malaysia from the perspectives of laws and public perception. Researchgate.Net, 33(3), 709–718. https://doi.org/10.17576/jkukm-2021-33(3)-29
Bolarinwa, O. (2015). Principles and methods of validity and reliability testing of questionnaires used in social and health science researches. Nigerian Postgraduate Medical Journal, 22(4), 195. https://doi.org/10.4103/1117-1936.173959
Bryman, A. (2016). The research methodology for the development of a kaizen costing framework suitable for indigenous construction firms in Lagos, Nigeria. Proceedings of Association of Researchers in Construction Management (ARCOM) Doctoral Workshop Research Methodology 10th April 2015, April, 1–12. https://doi.org/10.13140/RG.2.1.3395.1600
Ciptono, A., Setiyono, S., Nurhidayati, F., & Vikaliana, R. (2019). Fuzzy Delphi method in education: A mapping. Journal of Physics: Conference Series, 1360(1). https://doi.org/10.1088/1742-6596/1360/1/012029
CORDONI, D. (2022). LEAN MANAGEMENT ATTRAVERSO UN’ANALISI BOTTOM-UP IN UN’AZIENDA MANIFATTURIERA: IL CASO ALCI. https://tesi.univpm.it/handle/20.500.12075/13893
Dalkey, N., & Helmer, O. (1963). An Experimental Application of the DELPHI Method to the Use of Experts. Management Science, 9(3), 458–467. https://doi.org/10.1287/MNSC.9.3.458
Dhingra, A., Kumar, S., Assurance, B. S.-I. J. of S., & 2019, undefined. (n.d.). Cost reduction and quality improvement through Lean-Kaizen concept using value stream map in Indian manufacturing firms. Springer. Retrieved September 17, 2023, from https://link.springer.com/article/10.1007/s13198-019-00810-z
Frumence, G., Mboera, L., Katale, B., … C. S.-J. of global, & 2021, undefined. (n.d.). Policy actors and human and animal health practitioners’ perceptions of antimicrobial use and resistance in Tanzania: A qualitative study. Elsevier. Retrieved September 11, 2023, from https://www.sciencedirect.com/science/article/pii/S2213716521000606
Garza-Reyes, J. A., Christopoulos, C., Kumar, A., Luthra, S., González-Aleu, F., Kumar, V., & Villarreal, B. (2022). Deploying Kaizen events in the manufacturing industry: an investigation into managerial factors. Production Planning and Control, 33(5), 427–449. https://doi.org/10.1080/09537287.2020.1824282
Garza-Reyes, J. A., Kumar, V., Chaikittisilp, S., & Tan, K. H. (2018). The effect of lean methods and tools on the environmental performance of manufacturing organisations. International Journal of Production Economics, 200. https://doi.org/10.1016/j.ijpe.2018.03.030
Govindasamy, P., Abdullah, N., & Ibrahim, R. (2023). Employing Modified Design and Development Research (DDR) Approach to Develop Creativity Clay Module to Teach Special Educational Needs (SEN) Students with Learning Disabilities. International Journal of Academic Research in Business and Social Sciences, 13(3). https://doi.org/10.6007/IJARBSS/V13-I3/15773
Hameed Qureshi, M., & Farooq, S. (2020). Assessment of Industrial Cluster Policies in Viet Nam: The Role of Special Economic Zones in Attracting Foreign Direct Investment. Perennial Journal of History (PJH, IV No. I(1), 96–118. https://doi.org/10.52700/pjh.v4i1.143
Iskandar, M., Letters, A. A.-M. S., & 2019, undefined. (2019). Relationship between National Automotive Policy (NAP), innovation and automotive vendors’ performance in Malaysia. M.Growingscience.Com, 9(8), 1181–1198. https://doi.org/10.5267/j.msl.2019.4.022
ISNAINI, D., DANILWAN, Y., MANSUR, D., 유통과학연구 G. I.-, & 2021, undefined. (n.d.). Perceived Distribution Quality Awareness, Organizational Culture, TQM on Quality Output. Dbpia.Co.Kr. Retrieved September 11, 2023, from https://www.dbpia.co.kr/Journal/articleDetail?nodeId=NODE11332587
J. Ellis, T., & Levy, Y. (2008). Framework of Problem-Based Research: A Guide for Novice Researchers on the Development of a Research-Worthy Problem. Informing Science: The International Journal of an Emerging Transdiscipline, 11, 017–033. https://doi.org/10.28945/438
Jittrapirom, P., Marchau, V., van der Heijden, R., & Meurs, H. (2020). Future implementation of mobility as a service (MaaS): Results of an international Delphi study. Travel Behaviour and Society, 21, 281–294. https://doi.org/10.1016/J.TBS.2018.12.004
John W. Creswell. (2014). RESEARCH DESIGN Qualitative, Quantitative and Mixed Method Approaches (K. Lk. Vicki Knight, JEssica Young, Ed.; 4th editio). SAGE Publications Asia-Pacific Pte. Ltd.
Kuchiki, A. (2007). A Flowchart Approach to Malaysia ’ s Automobile Industry Cluster Policy. 120, 1–30.
Kumar, K., Zindani, D., & Davim, J. P. (2019). Industry 4.0. https://doi.org/10.1007/978-981-13-8165-2
Latif, A., & Saari, S. (2023). Government Initiatives to Promote Adoption of IR4.0 Technologies in Manufacturing. Digitalization and Development: Ecosystem for Promoting Industrial Revolution 4.0 Technologies in Malaysia, 228–242. https://doi.org/10.4324/9781003367093-13
Mackus, A. J. M., Merkx, M. J. M., & Kessels, W. M. M. (2018). From the Bottom-Up: Toward Area-Selective Atomic Layer Deposition With High Selectivity. Chemistry of Materials. https://doi.org/10.1021/acs.chemmater.8b03454
Marzukhi, H., & Mawar, M. Y. (2020). A Proposed Methodology on Developing an Awareness Model of Competitiveness and Quality Standards for Smallholders in The Oil Palm Industry. Proceeding of the 7th International Conference on Management and Muamalah, 2020(ICoMM), 187–197.
Ocello, E. (2019). POLICY DEPLOYMENT FOR CONTINUOUS IMPROVEMENT IN PUBLIC HOSPITALS. From Kaizen Initiatives to a Kaizen Initiative Program: an action research. https://ricerca.unityfvg.it/entities/publication/49b1b017-529f-42c2-94e2-be08efc482df/details
Oztemel, E., manufacturing, S. G.-J. of intelligent, & 2020, undefined. (2020). Literature review of Industry 4.0 and related technologies. Springer, 31(1), 127–182. https://doi.org/10.1007/s10845-018-1433-8
Pakeltiene, R., & Ragauskaite, A. (2017). Creative synergy as a potential factor for the development of social innovations. Research for Rural Development, 2, 174–181. https://doi.org/10.22616/RRD.23.2017.065
Roy, A., Bakpayev, M., Boninsegni, M. F., Kumar, S., Peronard, J. P., & Reimer, T. (2023). Technology-enabled well-being in the era of IR4.0: marketing and public policy implications. Journal of Consumer Marketing, 40(4), 431–444. https://doi.org/10.1108/JCM-11-2021-5021
Schuckmann, S. W., Gnatzy, T., Darkow, I. L., & von der Gracht, H. A. (2012). Analysis of factors influencing the development of transport infrastructure until the year 2030 - A Delphi based scenario study. Technological Forecasting and Social Change, 79(8), 1373–1387. https://doi.org/10.1016/j.techfore.2012.05.008
Seni Issn ; Mariappan, K., Khairani, P. Z., & Chanthiran, M. Z. (2022). Design and Development Research (DDR) Approaches in the Development of Koin-Art Cooperative Learning Model for Student of Inclusive Education Program. Kupas Seni, 10, 66–77.
Sexton, J. B., Schwartz, S. P., Chadwick, W., Rehder, K. J., Bae, J., Bokovoy, J., Doram, K., Sotile, W., Adair, K. C., & Profit, J. (2016). The Associations Between Work–life Balance Behaviours, Teamwork Climate and Safety Climate: Cross-Sectional Survey Introducing the Work–life Climate Scale, Psychometric Properties, Benchmarking Data and Future Directions. BMJ Quality \& Safety. https://doi.org/10.1136/bmjqs-2016-006032
Siew Yean, T. (2021). Global Trends and Malaysia’s Automotive Sector: Ambitions vs. Reality.
Suárez-Barraza, M. F. (2023). What Is KAIZEN? Definition, Characteristics, Guiding Principles, Techniques, and Tools. KAIZEN-21, 13–23. https://doi.org/10.1108/978-1-80455-844-720231003/FULL/HTML
Sulaiman, H. F., Ismail, R., Mohd Yusoff, H., Anuar, N., Mohd Jamil, M. R., & Daud, F. (2020). Validation of Occupational Zoonotic Disease Questionnaire Using Fuzzy Delphi Method. Journal of Agromedicine, 25(2), 166–172. https://doi.org/10.1080/1059924X.2019.1666763
Sunder M, V., & Prashar, A. (2020). Empirical examination of critical failure factors of continuous improvement deployments: stage-wise results and a contingency theory perspective. Int J Prod Res, 58(16), 4894–4915. https://doi.org/10.1080/00207543.2020.1727044
Takakuwa, S., Veza, I., & Celar, S. (2018). “Industry 4.0” in Europe and East Asia. Annals of DAAAM and Proceedings of the International DAAAM Symposium, 29(1), 0061–0069. https://doi.org/10.2507/29TH.DAAAM.PROCEEDINGS.009
Theresia, L., Sudri, N., … Y. M.-P. of the 3rd, & 2022, undefined. (n.d.). Relationship between kaizen, employees work, and quality of service A PLS-SEM approach. Ieomsociety.Org. Retrieved September 17, 2023, from http://ieomsociety.org/proceedings/2022malaysia/143.pdf
Yuik, C. J., Perumal, P. A., & Feng, C. J. (2020). Exploring critical success factors for the implementation of lean manufacturing in machinery and equipment SMEs. Engineering Management in Production and Services, 12(4), 77–91. https://doi.org/10.2478/emj-2020-0029