APS Trading Kaizen Project — Q1 2025

This is the first case in the “Eight Lean Examples from Bulgarian Industry” series, presenting measurable results achieved by participants in the Lean Champions: 5S and Kaizen initiative.

The series demonstrates how Lean Champions creates practical value through measurable improvements, shared good practices and community support, without requiring participants to have prior Lean experience.

Objective

Reduce the production time for one module by 30%.

Main challenges

• No standard work diagrams
• No production-capacity data
• Reliance on overtime

Methods used

The team used 5S, value-stream mapping, time studies, line balancing, layout improvements and standard-work documentation.

Results

• 39% reduction in the number of operators required
• 38% reduction in production time
• 35% reduction in labour cost per unit

Join Lean Champions

Manufacturing companies interested in discussing participation can request an on-site introductory meeting through the existing Lean Champions registration process.