Standardizing a Divided Pallet for Work Kits

During production, work kits belonging to different orders were stored together on the same pallet, stacked and mixed with each other.This created a risk of mixing different orders and made it difficu...

25 September 2026

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Yener Esen

KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:

BEFORE

State before kaizen

Different order kits were stored on the same pallet.
Kits were stacked on top of each other.
Kits belonging to different orders could become mixed.
Operators had to move upper kits to reach the kit underneath.
Kit searching and separation created additional time loss.
Bending, reaching and carrying created unnecessary ergonomic movements.
The existing pallet arrangement was not standardized.

A production area where different order kits are stacked together on a pallet. Kits are placed on top of one another without defined compartments, forcing the operator to move upper kits to reach the required kit.
Main message:
Mixed and stacked kits create searching, unnecessary movement and ergonomic problems.

Caption: A production area where different order kits are stacked together on a pallet. Kits are placed on top of one another without defined compartments, forcing the operator to move upper kits to reach the required kit. Main message: Mixed and stacked kits create searching, unnecessary movement and ergonomic problems.

AFTER

State after kaizen

The existing pallet was redesigned with dedicated compartments.
A separate location was created for each order kit.
Kit locations were clearly identified.
Kit definitions became visually visible.
Operators can directly access the required kit.
Unnecessary kit movement and searching were reduced.
The working area became more standardized.
The new arrangement improved both work safety and ergonomics.

The same pallet redesigned with clearly defined compartments for different order kits. Each compartment is labeled, allowing the operator to identify and access the required kit directly.
Main message:
Defined locations make every kit easier to find, access and handle.

Caption: The same pallet redesigned with clearly defined compartments for different order kits. Each compartment is labeled, allowing the operator to identify and access the required kit directly. Main message: Defined locations make every kit easier to find, access and handle.

Problem Statement / Theme

During production, work kits belonging to different orders were stored together on the same pallet, stacked and mixed with each other.

This created a risk of mixing different orders and made it difficult for operators to reach the kit they needed. To access a kit underneath, the kits above it had to be moved first, creating additional search time, unnecessary movement and awkward handling.

The existing pallet was redesigned with dedicated compartments for each order kit. Each compartment was clearly identified, allowing kits to be stored and accessed in a defined location.

The improvement eliminated unnecessary kit searching and moving, while creating a more organized and ergonomic work area.

Lean principle:
When every item has a defined place, searching and unnecessary movement become easier to eliminate.

Standardizing a Divided Pallet for Work Kits

KAIZEN A3 REPORT

BEFORE

AFTER

Problem Statement / Theme

Team Formation

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