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.
Don’t Judge a Book by its Cover
For part of my career, I worked for Dal-Tile in Dallas Texas. I was the environmental, safety, health, and mining liaison for our twelve manufacturing plants. My job was to help each plant stay compliant and safe, providing training and reporting support. We had a number of factories in Texas, and I visited each one and get to the know the employees and leadership. That way, I could develop a support plan that was mutually beneficial.
Kaizen Every Day – The Armstrong Lockout
In all my years doing continuous improvement work, I worked with teams during Kaizen events of short duration, or influencing continuous improvement behavior daily. Never did I think I would be doing 6 months straight of Kaizen. That is, until the Armstrong Lockout.
Even the Most Organized Person Can Improve
A global ceilings manufacturer wanted to improve the safety and productivity of its testing facility. Over the years, many capabilities had been added to the facility without regard to the needs of the technicians who worked there. Because of this and the lack of a managing system to ensure the organization and productivity of the facility, the technicians took it upon themselves to hold an annual “cleanup week” at the end of the year. All technicians would stop their project work and devote their time to go through equipment, materials, and spaces and clean out any clutter they felt they could get rid of.
Owning Their Solution in the Weld Shop
I have conducted many workplace organization Kaizens (5S) over the years. The results have always been dramatic. All of the teams were made up of production operators or office workers, with some mechanics assisting the team. The production operators or office workers owned the areas needing organization and the mechanics were able to do some of the more complex tasks needed during the Kaizen. All of the teams, that is, until I met my Weld Shop team. Five mechanics and an engineer, who underestimated what we could accomplish.