Get it Right Early

Small alignment problems at the beginning of a manufacturing process often become major quality, reliability, and productivity problems downstream. In this video, I share how a Reliability Kaizen helped one composite decking manufacturer dramatically improve flow by focusing on the earliest points in the process.

No Barrier too Big for the Team

Sometimes the biggest obstacle to improvement isn't the process, it's an unexpected crisis. In this video, I share how a Reliability Kaizen was interrupted by a plant evacuation, only to return stronger than before. It's a story about resilience, teamwork, and proving that no barrier is too big when people are committed to continuous improvement.

Building their Future

Guiding Principles

Once we removed conveyer guides, we improved the performance at the world’s largest ceiling plant.

Once we removed conveyer guides, we improved performance at the world’s largest ceiling tile plant.

Weld it in Place to Sustain it

Before I developed the Wheel of Sustainability, I had to find other ways to sustain our Kaizen solutions. In this case, we used a welder.

Plant Reliability Rollout - the Story of Mobile

I knew I had to do a better job protecting the plant managers and driving the cultural transformation.

Moving Mountains ... of Paint

Walking the shop floor (Gemba) showed us why the tiles were rotating in the paint booth. Now we knew what we had to do to solve the problem.

Stop and Smell the Roses

We were so close to setting a company record. Why was everyone so stressed out?

Saving is not Saving

Don’t walk over dollars to pick up dimes.

Little Things Mean a Lot

Small adjustments to levelness, squaring, and centering raised line performance drastically.

Things Aren't Always What They Seem

Simplifying the process greatly improved performance.

Simpler is Better

Removing equipment from the line made things flow more smoothly and productivity rose.