UNDERSTANDING THE EFFECTIVENESS OF KAIZEN EVENTS: AN INPUT–PROCESS–OUTCOME PERSPECTIVE FROM A MATURE LEAN CONTEXT

Kaizen events are widely adopted as short-term interventions aimed at improving operational performance while fostering employee involvement and continuous improvement capabilities. Despite their diffusion, empirical evidence on the mechanisms that ensure their effectiveness remains limited. In particular, the interaction between event design conditions and the internal dynamics unfolding during Kaizen events warrants further exploration. Drawing on Farris et al. framework, this study investigates how input variables, process variables, and their interrelationships influence learning-oriented outcomes of Kaizen events. In particular, the study intends to investigate to what extent the relationships identified by Farris et al. in a heterogeneous sample of manufacturing companies are generalizable and if these relationships still hold in organizations characterized by a highly developed and mature lean system. In addition, the study seeks to explore how Farris et al.’s model can be used as a managerial tool to improve the design and governance of kaizen events. Quantitative survey data from 22 Kaizen events conducted within a large manufacturing company, characterized by a very mature lean system, were analyzed using exploratory factor analysis, regression models, and mediation analysis. The findings show that process variables—particularly affective commitment to change—play a dominant role in shaping outcomes, while several input variables display counterintuitive effects as compared to Farris et al.’s framework. The study contributes to the literature by highlighting the central role of team dynamics and emotional engagement in sustaining Kaizen outcomes in companies characterized by mature lean systems and offers practical implications for the use of Farris et al.’s framework in the design and management of improvement initiatives.