Kaizen Event Facilitation
Solve Your Most Critical Business Problems in One Week or Less
Focused Kaizen facilitation that reduces safety risks, improves productivity, eliminates bottlenecks, shortens changeovers, and delivers sustainable results.
Average annual savings per Kaizen event: $1.2 Million
Common Manufacturing Challenges We Solve
Kaizen Ninja Facilitation helps manufacturers improve safety, productivity, reliability, quality, lead time, and changeover performance through focused, results-driven improvement events.
Reduce risk and create safer work environments.
95% risk reduction at a paper mill through standard work and compliance improvements.
Recover lost production time through SMED techniques.
Whisky bottle changeovers reduced from 7 hours to 2 hours, generating $3M annual savings.
Increase throughput without additional labor or equipment.
OEE improved from 52% to 75% at a vinyl siding plant, setting production records.
Reduce scrap, rework, and customer complaints.
Scrap reduced by 50% at a composite decking plant, generating $1.4M annual savings.
Eliminate chronic downtime and recurring equipment failures.
Jams reduced from 55 per month to fewer than 5 at a building products manufacturer.
Improve flow and shorten delivery times.
Procure-to-pay lead time reduced by 65% at a steel producer.
A Why Organizations Continue To Bring Us Back
"Our plant in Florida has now had three different Kaizen events led by Adam, and each one has been well worth the investment. He has a people-centered approach that not only helps you get the results you are looking for, but also gets people excited and involved, helping move your site culture toward one of improvement."
-Corbin Crutchfield, Quality Manager, Owens Corning
How Kaizen Ninja Facilitation Works
Sustainable improvement doesn't happen by accident. Here's the process we use to help organizations achieve and sustain measurable results.
Step 1
Identify the biggest opportunity.
We identify the highest-impact improvement opportunities before the event begins.
Step 2
Align leadership and engage the team.
Leaders and participants align around a clear objective, scope, and expected outcomes.
Step 3
Implement improvements.
Teams work together to eliminate waste, solve problems, and implement changes in real time.
Step 4
Build Sustainability Systems.
Accountability, leadership engagement, and reinforcement systems are built into the process.
Step 5
Measure Results And Sustain Gains.
Results are verified, tracked, and reinforced long after the event ends.
Why Most Kaizen Events Fail to Sustain
Most Kaizen events generate great ideas, strong engagement, and immediate improvements.
The challenge isn't achieving results during the event.
The challenge is preventing those results from disappearing six months later.
Without leadership reinforcement, accountability, communication, and recognition, organizations naturally drift back toward old habits and previous levels of performance.
That's why every Kaizen Ninja Facilitation incorporates the Wheel of Sustainability.
The Wheel of Sustainability Helps Organizations:
Maintain leadership focus
Create accountability
Reinforce desired behaviors
Keep improvement visible
Recognize success
Prevent backsliding
Because sustainable improvement isn’t an event.
It’s a leadership process.
A New Normal
"We now have a new normal. The team was 100% engaged, and the improvements we made are impossible to go back from."
-Scott DiCola, Lean Manager, GE Vernova
Real Results From Kaizen Ninja Facilitation
Every organization is different, but the goal is always the same: solve critical business problems, improve performance, and create sustainable results. Here are a few examples of what teams have achieved through focused Kaizen Ninja Facilitation.
Jams reduced from 55/month to 5/month.
A North Carolina Building Products Manufacturer reduced jams through reliability improvements, saving $1.1 million annually.
Yield increased from 88% to 95%
A Mississippi vinyl siding manufacturer reduced jams and scrap through line reliability improvements, saving $1.3 million annually.
Bottle changeovers reduced from 7 hours to 2 hours.
An Indiana whisky distiller saved more than $1.9 million in line time and capacity growth.
Delivery time reduced from 8 days to 3.5 days
A Pennsylvania consumer goods manufacturer eliminated all late fines from Amazon, resulting in a $1.2 million annual savings.
Travel reduced from 175 feet to 4 feet
A New Jersey turbine manufacturer converted batch processing to single piece flow, doubling capacity and increasing revenue opportunity by $10+ million.
Results that Last
"Adam helped our organization cut a line changeover to less than half the time it historically took us. More importantly, he gave us the tools and insights to sustain that success long after the event ended."
-Mike Bukowski, Process Excellence Manager, Sazerac
Why Clients Choose Kaizen Ninja Facilitation
Every Kaizen Ninja Facilitation is designed to deliver measurable business results while building ownership, engagement, and sustainability throughout the organization.
