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.
Peggy’s Toolbox
I’m always organizing things around the house. One winter, I cut the shapes of my tools into foam and lined the drawers of my tool box. It looked so nice, I showed it to my family so they could admire it too. They humored me, but didn’t seem very impressed.
On a trip to Costco, I bought a labeler. It seemed like something that might come in handy for one of my home organization projects. Peggy, my wife, asked me what I needed with one. I wasn’t sure, but it was inexpensive. What was the harm in having one?
Go With the Flow
I was engaged to help an electronics manufacturer improve the safety and productivity of a testing lab at their Breinigsville, PA location. The problem they were trying to solve was that it took too long from the time the equipment was received to the time the test report was delivered to the customer.
We took a Gemba walk of the lab. I knew that the lack of organization and visualization of the process were key contributors to the less than acceptable performance. George, the lab owner, had worked for the company for many years and had a system that worked for him, but others had no idea what was going on and how they could help.
If Everyone’s Responsible, Nobody’s Responsible
I visited a consumer goods factory in Pennsylvania. They were profitable, but concerned their ability to service customer orders was deteriorating. I met with plant leadership and took a Gemba walk through the distribution center.