International Journal of Engineering Applied Sciences and Technology, 2021 Vol. 6, Issue 4, ISSN No. 2455-2143, Pages 311-317 Published Online August 2021 in IJEAST (http://www.ijeast.com) 311 KAIZEN EXECUTION IN DIGITAL WAY Ashok kumar Dilip Sahu DPDS, Tata Technologies, Pune DPDS, Tata Technologies, Pune Ashutosh Sengar Rahul Kumar DPDS, Tata Technologies, Pune DPDS, Tata Technologies, Pune Abstract- The demand for a product in the market is very complex and to suit the taste of the customer, the product needs to be customized. This customization increases the product variety in the manufacturing plants which results in, difficulty in manufacturing operations such as an increase in inventory level against limited storage space, extra use of man and machine, and subsequent increase in cost. The competition among the competitor is growing stiffer day by day and thus, continuous improvement and lean manufacturing is the need of the hour to sustain in the market. This paper aims at the implementation of lean manufacturing concepts with the help of digital tools such as process simulation, discrete event simulation, digital factory, and ergonomics analysis and to evaluate the benefits of it. Keywords: Lean, Digital, Kaizen, Kitting, Discrete event simulation, assembly. I. INTRODUCTION The word Kaizen is derived from two Japanese words “Kai” and “zen”. “Kai” means change and “zen” means for the better [9]. Thus, Kaizen means "change for the better" or "continuous improvement." It is a business philosophy regarding the processes that continuously improve operations and involve all employees. Digital Kaizen in this paper refers to the concept of using digital tools such as Discrete Event Simulation, Process Simulation, Ergonomics Analysis and Digital Factory, in the process of Kaizen. Digital Kaizen gives more flexibility, cost-effective, time-efficient, and resource independent approach, which helps to overcome the barriers of Lean Manufacturing. Thus, this paper aims to propose a project-based implementation approach to overcome these barriers. To achieve this feat one of the tool of the Lean Manufacturing, Digital Kaizen is used. II. METHODOLOGY The target of the Digital Kaizen was set to optimize the manufacturing operations to eliminate the waste. The two major wastes were identified, excess storage of inventory and over utilization of space. After the identification of the targets, a cross- functional kaizen team was established to achieve the objective. Kaizen team used the PDCA cycle for the control and continuous improvement of processes. PDCA stands for plan–do–check–act or plan–do– check–adjust. Here, the Plan denotes to establish processes to achieve desired results. Do stands to carry out the objectives from the Plan step. In the Check step, the data gathered from do phase is compared with the expected outcomes. "Do" and "Check" phases help to identify issues with the process. In the Act phase, actions are taken to eliminate the issues and to achieve the desired results. The detailed step by step process flow has been described in the flowchart, shown in Figure1.