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Streamlining the Customer Process Through Assembly Improvement
Mini Kaizen#80

Streamlining the Customer Process Through Assembly Improvement

In the existing process, industrial panel sockets were fully assembled and packaged before shipment. However, customer feedback and on-site observations showed that some of the assembly work performed...

24 September 2026
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KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:
S

BEFORE

State before kaizen

  • Industrial panel sockets were fully assembled before shipment.
  • Products were packaged after complete assembly.
  • Some assembled components were removed again by the customer.
  • The customer had to disassemble parts before using the product.
  • The same components could effectively be handled twice.
  • Manufacturer assembly time was 5 minutes.
  • Customer disassembly took approximately 2–3 minutes.
  • The process included work that did not create value for the customer.
Industrial panel sockets are completely assembled and packaged before shipment. Some components that have already been assembled are later removed by the customer, creating unnecessary work on both sides. Main message: Assemble it once—only if the customer actually needs it that way.
Caption: Industrial panel sockets are completely assembled and packaged before shipment. Some components that have already been assembled are later removed by the customer, creating unnecessary work on both sides. Main message: Assemble it once—only if the customer actually needs it that way.

AFTER

State after kaizen

  • The assembly process was reviewed together with the customer.
  • Only the components that needed to be assembled before shipment were retained.
  • Other components were prepared separately and shipped with the product.
  • Manufacturer assembly time was reduced from 5 minutes to 2 minutes.
  • Customer disassembly was completely eliminated.
  • Unnecessary handling was reduced for both sides.
  • The overall customer process became simpler and more efficient.
The industrial panel socket is prepared according to the customer's actual process needs. Only the necessary components are assembled before shipment, while other components are prepared separately for the customer. Main message: The right level of assembly for the right customer process.
Caption: The industrial panel socket is prepared according to the customer's actual process needs. Only the necessary components are assembled before shipment, while other components are prepared separately for the customer. Main message: The right level of assembly for the right customer process.

Problem Statement / Theme

In the existing process, industrial panel sockets were fully assembled and packaged before shipment. However, customer feedback and on-site observations showed that some of the assembly work performed by the manufacturer was later removed or repeated by the customer.

The process was therefore reviewed together with the customer.

Only the components required to be assembled before shipment were retained in the assembly process, while other components were prepared and shipped separately.

As a result, the manufacturer's assembly time was reduced from 5 minutes to 2 minutes. The customer's unnecessary disassembly activity, which previously took approximately 2–3 minutes, was also completely eliminated.

The improvement created a simpler process for both sides while reducing work that did not add value for the customer.

Lean principle:
A process becomes leaner when we improve the entire value stream—not just our own operation.

Kaizen image

Team Formation

S

Salih YILMAZ

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