Continuous Improvement Model for Small Scale Manufacturers in Kenya

Abstract

Continuous Improvement (CI) is a quality management philosophy that approaches the challenge of product and process improvement as a never ending process of achieving small wins. Quality management (QM) cannot be assured unless some objective assessments are undertaken. A number of tools and techniques are available to conduct such analysis. Some of these tools include flow charts, Pareto analysis, histograms, scatter diagrams, pie chart, cause and effect diagrams, and brainstorming among others. Several CI models and methodologies have been developed that integrate the use of these tools in the operations of the firm. A preliminary survey indicated that the status of the use of these models in Kenya was unknown. A literature review indicated the difficulties encountered in using these quality improvement tools as not knowing what quality tool to use, using a quality tool incorrectly, using a quality tool for the wrong application, and not knowing when to use a quality tool. The objectives of this research were to carry out a survey on the status of use of the CI models in Kenya, and to develop and validate a computer based CI model applicable to small scale manufacturers. The model aids in tool selection in the quality improvement projects. A survey was carried out by questionnaires, site visits and interviews to help determine the status of CI in Kenya. 174 questionnaires were sent to various manufacturing organizations from which 58 companies responded and they were all found usable. The survey findings revealed that there is a general awareness of the quality in the Kenyan manufacturing sector but there is a statistical correlation on the level of implementation and size of the company, age of the company and target market for the firm’s products. An algorithm that integrated CI methodologies and tools was developed and validated by testing it in two small scale manufacturers. The computer code allowed the user to identify the correct tool at the proper time in the problem-solving process. This assisted the problem solver to efficiently and effectively work toward problem solution. The research contributed to a general understanding of the extent of the use of CI with respect to quality management among the Kenyan manufacturers, and the developed computer code will find use in among the Kenyan manufacturers who are keen on improving the quality of their products by reducing the number of defects or predicting defects from their operational data.