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.
Squarely in the Middle of the Action
How asking a better question and slowing things down unlocked a stubborn reliability problem.
Hope is a Precious Commodity
I’m passionate about helping teams improve the reliability of their processes, using basic yet effective techniques to immediately boost the performance of their manufacturing lines. The best part is that the team can see and feel the results, and the techniques I teach are easy to learn and transferable to other lines and processes within the facility.
Simpler is Safer, Lighter, and Better
I was in Florida, working with a residential building products manufacturer on our second Kaizen event together. This time, we focused on improving materials delivery to the production lines. The tasks were challenging, physically demanding, and slow, leading to high turnover in the material handling position.
Plant Reliability Rollout – the Story of Mobile
I was a corporate industrial engineer at Armstrong World Industries. From time to time, I was given projects that impacted all facilities around the world. John, our manufacturing VP, was hired from an outside company. He was determined to have an accurate measure of performance, to compare facilities, and identify the highest value opportunities for improvement and investment.
Things Aren’t Always What They Seem
In 2011, Armstrong’s Marietta ceiling plant was utilizing technical resources and replacement workers to run the plant. Management and the labor union were unable to come to an agreement around their contract, and for seven months, the union workers were locked out.