Kaizen Success Stories
Real Manufacturing Results. One Kaizen at a Time
Explore real-world Kaizen success stories showing how manufacturing teams solved critical problems, improved performance, and created sustainable results.
An Incorrect Measure of Success
I used to think customer acquisition was the most difficult and challenging aspect of my business. Once I realized customer retention is top priority, it changed my perspective and approach.
Value for the Customer
After many years, I was able to influence my number one client to take their Gemba walk to the next level of performance. When the hourly production operator stood up and gave his perspective, it changed the mind set of the leadership team.
My first VSM for a non-manufacturing process
I applied Lean thinking exclusively to manufacturing processes for many years of my career. I wasn’t able to stretch my thinking beyond what I could see – the production of a physical product and how it impacts the customer, business, and employees. I conducted Value Stream Mapping (VSM – a strategic planning approach based on the view of the customer) sessions for many manufacturing facilities and we were able to identify countless opportunities to significantly improve safety, productivity, quality, and customer service. I developed a reputation for my ability to engage teams and facilitate complex sessions.
Don’t be afraid to ask for help
I had many stops in my corporate career. I worked in furniture, ceiling grid, ceiling tile, ceramic tile, and vinyl flooring all over the world. My most challenging assignment was working for Dal-Tile in Dallas Texas. I was the environmental, health, safety, mining, and industrial engineering liaison for the twelve manufacturing locations around the country.
Raising the bar for quality
Amstrong World Industries and Worthington Steel combined forces to create the number one ceiling grid manufacturer in the world. It didn’t start out that way, as employees of both companies were feeling their way through the combination of cultures.
The Ship that Didn’t Sail
Sometimes, even though you know you could help a prospect, they don’t feel the same way. This is one of those stories about my inability to create alignment with a business leader.
Rally to the Customer
Armstrong World Industries makes billions of square feet of ceiling tiles every year, shipping to locations all around the world. Most of these tiles are white. The remainder are off-white or a few standard colors. If a customer wants non-standard colors, until recently, Armstrong used an outside vendor.
What Process Improvement Partners Can Do for Your Team
Process Improvement Partners LLC offers a variety of services that help teams achieve breakthrough results. Some are narrow in scope, while others are strategic in nature. Some are quite simple, and others are extremely complex. In all cases, we strive to apply the right service to our customer’s needs, providing hands-on assistance, where needed.