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The Sixth Sigma: Achieve Breakthrough Performance Using Six Sigma

Wednesday, April 21, 2010

Kaizen events at HP Indigo Plant

HP teams deploy kaizen to streamline the routine at its facilities for Indigo products. ...

... "Presses are assembled strictly to order, and their just-in-time production is governed by Japanese-inspired rules of lean manufacturing. Team-driven kaizen events are used to solve problems and maximize throughput at every stage. " ...


Via Print CEO: HP Indigo plant

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Friday, March 12, 2010

Kaizen Burst of Improvement

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Thursday, March 04, 2010

Integrate Kaizen and Six Sigma to

... improve the repair process. Indy uses kaizen and Six Sigma to accelerate pothole repairs using the: "Chuckhole Kaizen Response, implemented with the assistance of Eli Lilly Six Sigma black belts ... " http://bit.ly/c2BhQh

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Friday, February 26, 2010

Kaizen Procurement Process Reduces Steps and Delays

Procurement organization applies kaizen methods to achieve process improvements. ...

... "DAS Procurement Services received NASPO recognition by finishing fourth among all state procurement operations for its efforts to improve Iowa’s procurement process by utilizing the Kaizen method. This initiative reduced the steps of the bid process by 42 percent; reduced delays in the process from 33-35 percent; " ...


http://bit.ly/d0JXZ3

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Tuesday, February 23, 2010

LSS Kaizen Event exceeds expectations for CFO

Office of CFO provides insights into the application of Lean Six Sigma into the GSA continuous improvement processes. ...

... "We first applied LSS when presented with a major problem – too many worksheet adjustments outside of our financial system of record and the potential for endangering our clean opinion. As CFO, this made me stop in my pumps – we needed to solve this problem immediately. We introduced LSS to a group of GSA’s accountants and asked them to conduct a kaizen event to determine how to reduce the number and dollar volume of adjustments to our financial statements conducted outside of our financial system of record. The worksheet adjustment team exceeded my expectations and identified several significant actions we could take to ensure adjustments were made earlier in the workflow. Most importantly, we achieved our overall goal – retaining our GSA FY 2009 clean opinion. " ...


http://bit.ly/9x9IJg

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Wednesday, February 10, 2010

Kaizen DNA

Toyota deals with its quality problems by initiating another recall. The company's president apologizes for the situation and acknowledges that the automaker is not perfect. ...

... "Whenever we find flaws or mistakes we make sure to correct them ... That's part of our kaizen (continuous improvement) DNA, he added. " ...


Via Wall Street Journal: Toyota Recall, Prius Hybrids

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Saturday, February 06, 2010

Kaizen Factory Configuration

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Sunday, November 22, 2009

Donaldson Kaizen Optimizes Business for Future with Operational Efficiency

Bill Cook, Donaldson's Chairman, President and CEO discusses the company's results and how it is positioned to operate in the future business environment. Donaldson reported a decrease in sales and earnings but is experiencing sequential operating improvements. The company is deploying a kaizen culture in project portfolio fashion to drive operational efficiency broadly in its products, procurement, and business processes. Donaldson sees its kaizen strategy as a platform for shifting the business to a new level of performance, optimized to compete in the future. ...

... "However, given that we’re expecting a gradual economic recovery rather than a strong V-Shaped one, we will continue to focus on our cost control initiatives to ensure that we balance our expenses with our current and projected business levels. Under our corporate philosophy of Kaizen or continuous improvement, we have dozens of project teams working across our organization to further reduce costs and improve our operating efficiencies, in our product designs, in our purchase materials, manufacturing processes, and our operating departments. Our objectives include not only managing today’s costs, but also optimizing our business for the future. We also have on going return on investment initiatives focused on implementing long term improvements in our working capital utilization specifically inventory, accounts payable and accounts receivable. All this work has paid big dividends so far and will continue to do so. " ...


Via Seeking Alpha: Donaldson Company Management Earnings Discussion

Company facts: Donaldson Company, Inc., headquartered in Minneapolis, is a leading worldwide provider of filtration systems and replacement parts.

Donaldson energy efficiency program uses these techniques to identify opportunities: Donaldson Lessons Learned and Case Study for Energy Efficiency (PDF): "Process to identify opportunities: Six Sigma, Kaizen/Lean utility Audits, Leased Building Audit, HQ Campus formal Process Efficiency program. "

Donaldson creates and sustains its kaizen / lean culture through education and engagement. Recent Donaldson employee and now lean consultant, Mack Story, shares his experiences at the company, where he developed internal lean certification program and engaged with the manufacturing workforce through training and kaizen events: Mack Story - LinkedIn. Karl Johnson, who was an operations manager at Donaldson during his career, managed Six Sigma black belts and engaged in a number of improvement activities as a routine part of his role: Karl E Johnson - LinkedIn: Lean Techniques, Six Sigma Projects, 5S Improvements, Kaizen events, for example.

Donaldson Filtering

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Monday, October 26, 2009

Kaizen Events Target Operational Efficiency at Donaldson

Management discusses Donaldson Company performance and repositioning the operating costs for the revised business forecast. Donaldson is using a portfolio of kaizen-driven project to impact operational efficiencies. ...

... "Under our corporate philosophy of Kaizen, or continuous improvement, we have dozens of specific projects working across our organization to further reduce costs and improve our operating efficiencies in our product designs, purchased materials, our manufacturing processes and our operating departments. Our objective includes not only managing today’s cost but also optimizing our business for the future. We also have ongoing return on investment initiatives focused on implementing long-term improvement in our working capital utilization ... " ...


Via Seeking Alpha: Donaldson Company Earnings Call

Donaldson business relies on kaizen tactics

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Tuesday, September 29, 2009

Kaizen Service Model Empowers Workforce to Build Zippy Processes

Zipcar CEO Scott Griffith discusses his company's growth strategies and outlook for scaling the business. Zipcar has creatively integrated lean manufacturing techniques into its service business model, empowering its workforce to manage kaizen events and embrace continuous improvement in its business processes, especially the processes with customer touch points. ...

... "We’re one of the first companies to use that in a service model. We’ve now got kaizen-trained employees in many parts of the company who are managing everything from how we manage parking tickets to how do we handle accident claims. " ...


Via Mass High Tech: Zipcar CEO Perspectives

Zipcar uses kaizen techniques to improve services

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Monday, September 21, 2009

Lean Health Care Education Includes Hospital Kaizen Events

University of Iowa teaches a lean healthcare program where students lean to map processes, eliminate waste to the benefit of patients, and apply their skills to real-world hospital situations. ...

... "The Lean process is one of the teaching focuses of the Tippie School of Management's MBA program, including Lean health care. In one course, students have participated in Lean events at both Mercy Hospital and University of Iowa Hospitals and Clinics. " ...


Via : UI Lean Health Care

Iowa Healthcare Collaborative supports lean applied in health care.

Iowa hospitals use kaizen events to identify improvement opportunities.


Lean healthcare process

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Wednesday, August 19, 2009

Porsche Kaizen Efficiency

New Porsche leader brings experience in operational excellence, using kaizen techniques to streamline automotive operations. ...

... "The secret of their success was the Japanese business philosophy of kaizen, which emphasizes a lean approach to manufacturing based on constant process optimization. Using the kaizen philosophy, Wiedeking and Macht streamlined Porsche within a short period of time. " ...


Via BusinessWeek: Michael Macht, Porsche

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Saturday, July 25, 2009

Kaizen Quick Changeover

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Tuesday, July 21, 2009

Trane Lean Culture Kaizen Events

Trane has implemented Ultriva kanban systems to augment the lean leadership culture that is has cultivated. ...

... "From a higher level of Ingersoll-Rand -- even our CEO participates in 2 kaizen events a year at different plants, so it's becoming part of our culture for sure, noted John Young, Materials/Supply Chain Leader of TRANE Residential SystemsVidalia, GA. " ...


Via Ultriva: TRANE Residential Systems lean organization (PDF)

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Wednesday, July 01, 2009

Flextronics Kaizen Practices Drive Improvements for the Customer

Flextronics Paderborn Germany site has mapped its value streams and continually implements improvements using Kaizen techniques. These improvements accelerate the efficiency of the operations over time, as individual changes may be hard to notice, but cumulative effects are signficant. ...

Flextronics German operations leverage lean techniques

... "We are using the Kaizen cards to record and implement improvements to our workspace. Even changes that seem little at first can have a major impact on the quality and speed of our production. " ...


Via evertiq: Flextronics Lean




View Larger Map

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Monday, June 22, 2009

GM Kaizen

GM's Tom Stephens brings his personal kaizen to the product development job. ...

GM Tom Stephens

... "I'm here to defend Tom, for one simple character trait: He's a tinkerer. He has devoted his entire life to making things a little bit faster, a little bit more durable, a little bit more reliable. " ...


Via Automotive News: Tinkering GM

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Saturday, May 16, 2009

Lean Machine Shop

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Tuesday, April 21, 2009

Lean Kaizen Blitz

Company embraces lean and kaizen principles with education and action ... putting their learning into play with a first wave of opportunities from the kaizen blitz event. ...

... "Through exhaustive effort, working 10 or more hours every day, 50 areas of opportunity were documented and prioritized by their level of impact and difficulty to implement. " ...


Via American Printer: Business Stationary

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Wednesday, March 25, 2009

Lean Proactive Business Model

Lean Workforce Training Enables Culture Transformation
New Zealand manufacturer sees strong productivity benefits from lean manufacturing. The workforce culture has been transformed to one that contributes ideas freely to proactively improve the process. ...

... "Also known by its Japanese term Kaizen, which means continuous improvement, Mr Cook said lean manufacturing had transformed his business from a reactive organisation to a proactive one working daily to improve itself and meant it took Stainless Design about half the time it used to to process work. " ...


Via Stuff.co.nz: Model T

Stainless Design Workforce Training Program: "Everyone in the company is, and has been, involved in training in Lean principles and implementing improvement projects throughout the business. All these projects will provide significant operational and business performance improvements. "

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Tuesday, March 10, 2009

Kaizen Respect

Learn how kaizen improves leadership capabilities. ...

... "Respect. Kaizen teaches respect for people, time, resources, and differences in viewpoint, all qualities of an effective leader. " ...


Via The Manufacturer: 10 Ways of Kaizen

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Monday, January 12, 2009

Lexus Hybrid RX Improves with Kaizen

Lexus RX hybrid built with kaizen techniques
New Lexus hybrid vehicle incorporates efficiency and performance updates enabled through the deployment of kaizen techniques throughout the design, development, and manufacturing processes. ...

... "The Lexus Hybrid Drive in the new RX is a perfect example of how Lexus uses kaizen to improve its vehicles, said Lexus Vice President and General Manager Mark Templin ... " ...


Via The FINANCIAL: Lexus Hybrid Drive

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Saturday, December 20, 2008

Kaizen Muda Intro

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Friday, December 12, 2008

Vectron Six Sigma Manufacturing

Vectron practices lean and Six Sigma to improve its manufacturing process and product quality. In doing so, it embraces the methodology and creates a enterprise variant that works in its culture. ...

... "The facility has adopted lean manufacturing practices such as Kaizen and Six Sigma methods, all with an eye toward continuous facility and product improvement. The company follows a 16-point plan that has cut manufacturing cycle times in half compared to earlier attempts to reduce overall production times. " ...


Via Vectron: Frequency Control

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Thursday, December 04, 2008

Kaizen Idea Submission

Accelerate employee adoption of kaizen techniques by embracing idea submissions by the workforce. Reinforce the concept of open submission and transparency on how improvements are selected. ...

... "Don’t commit the mistake of giving only recognition to accepted employee ideas. Kaizen --- the Japanese word for continuous improvement --- is all about idea submission, and not acceptance, according to Matthew May ... " ...


Via BusinessWorld: Employee suggestions

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Saturday, November 22, 2008

Kaizen Discussion

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Sunday, October 19, 2008

Kaizen Culture

Experts from PPG Automotive Refinishing division will discuss kaizen and workforce culture at NACE session. ...

... "Kaizen Management: Building a Continuous Improvement Culture ... " ...


Via NACE 2008: Kaizen Session

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Monday, September 29, 2008

Toast Kaizen

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Worker Driven Kaizen

Teleflex lean manufacturing program create through passion of factory floor worker. ...

... "The impetus to go lean at the Teleflex hydraulics manufacturing plant came not from management, but from a production worker, Jay Zhang. He first heard about Kaizen when he worked as a design and process engineer at the Chang Sha Blower Factory ... " ...


Via Vancouver Sun: Kaizen works lean

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Wednesday, September 10, 2008

Kaizen Maps

Tutorial on Kaizen mapping ...

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Sunday, August 24, 2008

Kaizen Lean Energy Practice

Consulting firm, TBM Consulting, offers services in Lean Energy Efficiency, that leverage kaizen events to identify sources of energy waste to drive savings. ...

... "The $51 million (Rs 200 crore) revenue company monitors energy flows and holds kaizen events to spot waste and change processes to cut energy costs, Sharma said. Lean energy practices are different from what energy audit companies do, he said. " ...


Via Sify: TBM Consulting launches lean energy practice

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Monday, July 07, 2008

Chief Lean Officer Focuses on World-Class Efficiency

Intermet Corporation names Bob Flaherty into a newly created position of Chief Lean Officer to lead and mentor the company to world-class levels of efficiency. The new position reports the the CEO, Jeff Mihalic. ...

Chief Lean Officer is appointed

... "In his new role, Flaherty will work collaboratively with Intermet group presidents and the company's 10 plants to achieve world-class efficiencies while building upon the excellent lean foundation already in place throughout Intermet.

Previously, Flaherty spent nearly eight years at Toyota Motor Manufacturing in Georgetown, Ky., where he held various positions and responsibilities including start up preparation, training of associates on the Toyota Production System, various Production Engineering kaizen initiatives, and management of the stamping plant expansion. " ...


Via Intermet: Bob Flaherty Joins Intermet to Head Lean Initiatives

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Saturday, June 28, 2008

Changing Mindset and Culture with Kaizen in New Markets

As Japanese manufacturers expand into emerging markets, they meet challenges in transitioning their methodologies, culture, and workforce mindset into the new location. ...

... "The hardest part will be teaching the mindset and culture of kaizen, said Shouhei Kimura, a former factory manager who now heads Nissan's operations in India. Still, in recent months, the big Japanese automakers have announced a slew of new factories in the Middle East, South Asia and Latin America. " ...


Via Star-News: Emerging Markets

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Wednesday, May 14, 2008

Kaizen Brand Philosophy

Business owners of all sizes can leverage kaizen for success. ...

... "But I work with very demanding brands that apply the Japanese Kaizen philosophy to business, which constantly seeks better ways of doing things. " ...


Via Journal Evening Gazette: Driver's seat

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Thursday, May 08, 2008

Kaizen Constant Suggestions for Improvement

Kaizen principles are considered in public service for improving government. ...

... "Kaizen reaches every employee from the top floor to the floor sweeper, motivating each one to think and develop small but constant suggestions for doing whatever they do better, not once a day, or once a week, but always. " ...


Via Weymouth News: Clean with Kaizen

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Saturday, May 03, 2008

Kaizen Drives Change

Create new habits by incorporating kaizen principles into your life. ...

... "She recommends practicing a Japanese technique called kaizen, which calls for tiny, continuous improvements. " ...


Via New York Times: New Habits

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Monday, April 07, 2008

Semiconductor Manufacturing Benefits from Kaizen Events

Semiconductor manufacturer uses kaizen methods to sustain its improvement efforts and keep its facility capable of serving the industry needs at a competitive cost. ...

... "Small groups of workers and managers have spent a week or more in meetings - coming up with dozens of small steps that lead to productivity improvements. The kaizen events are modeled after methods that Japanese companies have used for decades to make their manufacturing operations the world standard for efficiency. " ...


Via Austin Statesman: Aging fab

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Saturday, March 22, 2008

Kaizen Plan

A project plan is an important element of an improvement initiative. However, the actual progress always varies from the plan in positive and negative ways. The plan provides a framework for comparison and a means to organize resources towards an objective. ...

... "Last week at the Batesville Casket Company, we completed an outstanding kaizen event in our Chihuahua, Mexico, plant despite the fact that our kaizen event was not even close to our original plan. " ...


Via Reliable Plant: Kaizen planning

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Wednesday, March 12, 2008

Toyota Kaizen Way Improves Customer Service

Toyota exec shares insights on Toyota and its kaizen principles. ...

... "Our customer service philosophy is fix it right the first time and to have lifelong customers. The term kaizen is one of the pillars of the Toyota way. " ...


Via The Augusta Chronicle: Toyota exec

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Wednesday, March 05, 2008

Kaizen Culture Compatible With Pace of Business Change

Does the kaizen culture position an enterprise to deal with the high-pace of business change? Leadership coach discusses managing meaningful change in an organization and the commitment necessary to endure successive waves of change.

... "What is so striking in today's workplaces is the sheer volume of those continuous improvement changes and the rate of change to the changes. " ...


Via Seattle Post-Intelligencer: Leading change

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Monday, March 03, 2008

Toyota Kaizen Carries Through to Motorsports

Toyota uses kaizen techniques to coordinate continuous improvement across its motorsports teams. The teams have confronted major challenges with this mindset. The knowledge of new race teams is leveraged across the organization. ...

Toyota kaizen mindset permeates the motorsports organization

... "Kaizen, a Japanese term commonly translated as continuous improvement, has been the ethos for Toyota's Motorsports operation. The way kaizen is achieved by the various teams in all three levels of NASCAR racing is by working together as one as much as possible. " ...


Via FOX Sports: NASCAR

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Wednesday, February 20, 2008

Lean Kaizen Techniques for Pharma

The pharmaceutical industry is undergoing a transformation where Six Sigma, lean, and kaizen methods can be used to instill the discipline necessary to achieve operational efficiencies and accelerate new product development. This article discusses techniques for blending the methodologies in the improvement process, such as the project charter and selection steps. ...

... "One approach is to integrate the chartering activity from the Six Sigma roadmap at the outset of the Kaizen blitz. The chartering exercise is crucial at the beginning of a Lean Kaizen in order to establish clear project success metrics, definition, expectations, communication, and milestones. " ...


Via Pharmaceutical Processing: Lean Kaizen

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Sunday, January 27, 2008

Kaizen Small Improvements Accumulate

Philosophy of workforce harmony is supported with a foundation of kaizen improvement to enable success of the enterprise. ...

... "They call it kaizen, or continuous improvement. ... Every employee of a company is focused on making many small improvements wherever they may be. It could be as simple as always maintaining a clean workplace, which reduces confusion and allows workers to remain focused. " ...


Via Grand Forks Herald: Wind turbine blade manufacturer

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Tuesday, January 15, 2008

Kaizen Costing

Indian manufacturers look to learn from Japanese management techniques, including creative approaches to cost management. ...

... "The shift has been from standard costing to kaizen costing (that is, continuous standard costing), and target costing (that is, longer term's budgetary control, meaning two or four years during the design stage). " ...


Via Hindu News: Cost Competitive Roadmap

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Friday, January 04, 2008

Toyota Production System Highlights

TPS reviewed in this vid. ...









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Wednesday, December 26, 2007

Toyota Kaizen Works in Vietnam

Kaizen principles can be successfully deployed anywhere in the world. Toyota replicates its success in Vietnam. ...

... "Regular kaizen (innovation) and optimization of all resources, especially supplying networks, have helped TMV provide customers with good products and services at reasonable prices. " ...


Via Saigon Times: Toyota Vietnam

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Sunday, December 16, 2007

Kaizen Love: Beyond the Factory

Can the principles of kaizen improve your life? Continuous improvement is not just for the factory. ...

... "Patience lets them test carefully and choose the best changes of the best, and then improve on them further. The deliberate process helps them know which changes were useful and important, and which were incidental. " ...


Via American Chronicle: Benefits of Kaizen

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Tuesday, December 11, 2007

Kaizen Innovative Methods

Toyota uses innovative methods to empower its workforce and improve the performance of the enterprise. ...

... "Toyota, whose $1.3 billion plant near Blue Springs will be the company's eighth North American assembly plant, is often associated kaizen, or continuous improvement, which is associated with its Toyota Production System. " ...


Via Trading Markets: Methods of Innovation

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Monday, December 10, 2007

Lean Kaizen Bootcamp

Lean Learning Center is offering a number of lean classes, such as a kaizen bootcamp, during 2008. ...

... "Lean Kaizen Workshop Boot Camp, a five-day, hands-on program with the majority of time spent at a manufacturing site; " ...


Via The Fabricator: Lean Learning Center Schedule

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Sunday, December 09, 2007

Small Shop Lean Manufacturing is a Journey

Company uses kaizen improvement opportunities to make progress into the lean manufacturing journey. ...











... from the Society of Manufacturing Engineers, SME.



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Saturday, December 08, 2007

Lean Software Support Visual Workplace

BubbleQuest offers a number of software modules, such as people, measures, organization, improvement, and training aids, that enable the implementation of lean techniques and kaizen improvements. ...

... "Kaizen is the process of continuous improvement using small, sustainable steps. The focus is on achieving small sustainable improvements by identifying & reducing sources of waste. " ...


Via Bubble Quest: Kaizen

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Wednesday, November 07, 2007

Kaizen Chindogu Connection

Here is interesting twist. Is this the inverse of Kaizen? ...

... "The difference is, of course, that Kaizen seeks to improve stuff we buy while Chindogu seeks to improve stuff we think. " ...


Chindogu Useless Usefulness

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Thursday, November 01, 2007

Kaizen Events Worth Time Investment

In some companies, it takes awhile before successes prove that kaizen events are worth the investment of time. ...

... "effects of a properly planned and executed kaizen event will pay for the perceived lost time of the participants many times over. " ...


Via Reliable Plant: Kaizen events

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Wednesday, October 17, 2007

Kaizen and IT-enabled Processes Expected to Make Healthcare More Efficient and Effective

Lean practices are applied to healthcare in the UK as management systems are improved. ...

UK healthcare systems are improved using kaizen methods

... "The Kaizen problem-solving system will also be applied to the turnaround time for lab tests, such as biopsy samples, which will help speed up diagnoses. Much of the work is likely to involve better use of IT systems ... " ...


Via The Scotsman: NHS Lothian

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Thursday, October 11, 2007

Kaizen Talent Management

Leverage the talents of your workforce to position your enterprise for success. ...

... "Quick and Easy Kaizen, a marvelous technique developed in Japan to open up people's hidden creative talent. " ...


Via IndustryWeek: Ninth Waste

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Saturday, October 06, 2007

Kaizen Best Practices

It's a challenge finding the right balance of kaizen efforts for products and processes. Here are some thoughts on best practices. ...

... "By thinking about the production process at the same time the product design is being evaluated, it's possible to optimize both. The second step is to lay out the process on paper and consider the different ways that it might be conducted. " ...


Via Reliable Plant: Review of kaizen practices

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Friday, October 05, 2007

Kaizen Principles Discussion

Kaizen principles discussed in video ...








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Monday, October 01, 2007

Kaizen Gradual Change in Formula One Materials

Formula One uses kaizen methods to improve
Formula One teams use kaizen improvement philosophy to create successful designs. ...

... "Such major changes in materials are unusual in modern Formula 1 but gradual changes are regularly implemented as the team pursues its kaizen philosophy of continuous improvement. " ...


Via Motorsport: Formula One

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Friday, September 21, 2007

TPS Toyota's Production System

Insights on TPS ...

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Sunday, September 09, 2007

Kaizen Facilitation Education Opportunity

Workshop teaches you to facilitate Kaizen and is scheduled for September 25, at Northeast State Technical Community College. ...

... "The Kaizen Facilitator Training Workshop will teach production and support personnel, who will be strongly involved in leading and the success of Kaizen events, a standard Kaizen process that can be used for implementing lean manufacturing tools, such as quick changeover, 5S, cellular/layout and TPM. " ...


Via Tri-Cities, Tennessee: Workshop Details

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Monday, July 02, 2007

Kaizen Medical Performance

The NHS changes the way it works to make sure patients always come first, using kaizen methods to engage and empower their workforce. ...

... "Scores of frontline staff were asked to submit their ideas on improving the way the NHS is run under a new lean management scheme. " ...


Via Scotsman: NHS Recognized For Kaizen Approach

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Wednesday, June 27, 2007

Six Sigma Benchmarking with Industry Leaders

Martin Guitar learns valuable improvement principles from benchmarking with Air Products. ...

Martin Guitars picks up some insights on Six Sigma tools from Air Products

... "Tools: Having techniques that are used to tackle waste and empower performance. Some examples include mapping, mistake-proofing, Six Sigma, kaizen and flow. " ...


Via IndustryWeek: Martin Guitar

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Sunday, June 24, 2007

Ariens Kaizen

Kaizen practitioner reaches 1000th kaizen blitz event. ...

Ariens Company uses kaizen to empower employees

... "Ariens Company employees recently conducted the 1,000th kaizen event aimed at reducing waste within the operation. " ...


Via Landscape Management: 1000th kaizen event

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Wednesday, June 06, 2007

Kaizen Enables Hospital Improvements

Hospital sees benefits from kaizen approach to continuous improvement, where the workforce is empowered to seek change. ...

... "Columbus Regional Hospital in Columbus, Ind., focused on changing the culture and environment in its surgical area to improve operations. Practice changes were driven by stringent data analysis, as well some newer methodologies, including Lean Six Sigma and Kaizen. " ...


Via Infection Control Today: Hospital Efficiency

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Sunday, June 03, 2007

Small Continuous Change, Entrepreneurs Toolbox

Entrepreneurs can sustain business success by enrolling the workforce in many, small improvements, using the kaizen style of management. ...

... "Shortly after World War II, Japanese companies created a management concept called Kaizen. The concept of Kaizen is to make small continuous changes and it includes everyone from the CEO to the janitors. " ...


Via USA Today: Entrepreneur Advice on Business Success

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Sunday, May 27, 2007

Lean Methods Fuel Fervor For Continuous Improvement

Lean methodology enables manufacturing or service companies to improve the enterprise. ...

... "Kaizen, or lean improvement events, and, when facilitated properly, they can be powerful. Everyone involved feels a part of the success of the event and many thirst for more. " ...


Via Appleton Post-Crescent: Lean Methods

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Saturday, May 26, 2007

Kaizen Change Empowers Shopfloor

TriMas Corp embraces kaizen principles as it shifts accountability for continuous improvement to shopfloor workforce. ...

Trimas Corp implements kaizen for transform its culture

... "In 2006 it was the inaugural winner of the Toyota Kaizen Blitz Marathon for reducing waste levels. The changes generally happen in a short order of time, Mr Saunders said. And from the perspective of management it empowers people doing the job to make a change. Kaizen change is driven by shop floor or office employees. " ...


Via Star News: TriMas Corp Goes Lean

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Wednesday, May 23, 2007

Kaizen Learning, A Way of Life

Want a better life? ... learn (or kaizen) ...

... "In the Japanese culture, continuous learning (they call it kaizen) is a key part of their lives. It's a belief that life is a journey and that knowledge can and should increase with every step taken. " ...


Via Community Press: Lifetime Learning

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Sunday, May 20, 2007

Reinvent Automotive Production Through Lean Manufacturing

Does the Chrysler sale offer opportunity to challenge Toyota for lean leadership? Will private capital have the patience for long-term methodologies, like kaizen and lean? We shall see. ...

... "And it is the chance of a lifetime for a car company to reinvent itself, to out-Toyota Toyota in lean manufacturing and vehicle quality. " ...


Via USATODAY: Chrysler Sale

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Wednesday, February 21, 2007

Lean Training Goes On Tour

Lean culture differentiates Japanese from US companies.

... "Instead of paying people to retire, a likely Japanese alternative would be to put people on kaizen (continuous improvement) teams, capitalizing on their experience and problem solving potential instead of paying them to stay at home. ... World Class Manufacturing is not a short-term concept. Justifying the hard work and application of resources to the improvement process is difficult if the focus is on quarterly reports. A fundamentally change in the way success is measured must be adopted if our economy is to remain viable and sustainable. " ...


Toyota Continues their March Past US Automakers: Lean Enterprise Training Announces Six City Tour Kicks off in Oregon ...

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Tuesday, January 02, 2007

Lean or Kaizen: How to Choose Right Tool

Upcoming seminar discusses choosing the right tool for your operational excellence challenge. ...

... "Six Sigma, Lean, or Kaizen? Using the Right Tool for the Right Problem, Live Internet Broadcast, Sponsored by SAP, in association with Intel and HP, Thursday, January 11, 2007 - 2:00 p.m. EST " ...


Via IndustryWeek: Using the Right Tool for the Right Problem

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Wednesday, December 27, 2006

Toyota Kaizen Poised to Eclipse GM

Toyota, built on a foundation of kaizen, is set to eclipse GM based on its business plan forecast for 2007. ...

... "Toyota's rise also would prove a victory of sorts for its unique corporate culture, the so-called Toyota Way, which is rooted in an obsession with craftsmanship and constant improvement, or kaizen. " ...


Via St Louis Today: Business

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India Kaizen: Automotive Manufacturing

India automotive manufacturing uses kaizen techniques to drive benefits. ...

... "In areas like factory layout and selection of equipment, production and quality control systems, kaizen and suggestion schemes, and the importance of training, Maruti followed Suzuki's advice with great benefit. " ...


Via Business Standard: Read

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Thursday, December 14, 2006

Kaizen: Deming Philosophy

Modern Postcard has the mindset for success, incorporating lean thinking into its methods for continuous improvement. ...

... "Hoffman also subscribes to W. Edwards Deming's philosophy of statistical process control, as well as to kaizen, the Japanese term for change for the better or improvement used in lean-manufacturing circles. " ...


Via Graphic Arts Monthly: Kaizen: Deming Philosophy: Picture Perfect

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Thursday, November 23, 2006

LeanSixSigma: Danaher Business System

Accenture partner discusses the transformation that is achieved through Lean Six Sigma implementation. Sustaining high performance that translates into ongoing profitability is the goal. And, lean manufacturing principles become the enterprise's diet. ...

... "At the level of daily management, kaizen events employ a diverse range of operational efficiency tools – including Six Sigma and value-mapping techniques – to eliminate such sources of waste as excess inventory, waiting time, overproduction and quality defects. " ...


Via The Manufacturer: Link

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Tuesday, November 21, 2006

Toyota Kaizen Culture: Texas Style

Toyota Texas plant builds new Tundra truck with kaizen culture ...

Toyota builds Tundra with kaizen efficiency in Texas

... "Reminders of the automaker's culture of kaizen -- or continuous improvement -- are everywhere as workers with Team Texas badges run slow-speed test production of the Tundra ... " ...


Via Reuters UK: Link

Greater San Antonio Chamber of Commerce info on Toyota Texas Plant ...

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Sunday, October 29, 2006

5S Program: Kaizen Compatible ...

Kaizen and 5S techniques leveraged together for success ...

... "First we have the kaizen improvement techniques and the 5S housekeeping program which are two effective productivity tools the company has in place, he said. " ...


Via Fiji Times: A tale of achievement ...

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Manufacturing Engineer Position: Understand Kaizen ...

Open position requires kaizen understanding ...

... "Requires a BS in Engineering and a minimum 5-9 years of experience in a manufacturing environment with heavy emphasis cost savings through improved processing. An understanding of Cellular Manufacturing, KanBan, Kaizen, Take time, Single Part Flow, Visual management, Poka-Yoke and 5's required. " ...


Via Spokesman Review: Link

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Kaizen Toyota Corolla Dependabiity ...

Toyota Corolla's dependability is a result of relentless focus on continuous improvement through kaizen. ...

Toyota Corolla's success is driven by kaizen ...

... "Every process -- from assembly operations to the paint shop, from bringing in parts to loading finished cars on trucks or trains -- has been refined. Toyota calls it kaizen, or continuous improvement. " ...


Via SanJose Mercury: The bestselling car ever

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Sunday, October 15, 2006

Kaizen Collaboration for Continuous Improvement ...

Evening seminar this Thursday on creating a kaizen culture ...

... "This Thursday: The Buffalo Section of the American Society for Quality, 5:30 p.m., Classics V Banquet and Conference Center, 2425 Niagara Falls Blvd., Amherst. Program: Kaizen: Creating a Culture of Collaboration for Continual Improvement, presented by Dave Hallett, Insyte Consulting. " ...


Via Buffalo News: Business calendar ...

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Wednesday, October 11, 2006

Government Kaizen Initiative

Local authority uses kaizen methods to improve services and their success is recognized. ...

Shire recognized for kaizen initiative

... "Following recognition at national level, Aberdeenshire Council's Kaizen initiative is now a beacon of excellence across Europe after taking an international award for continuous improvement.

The Aberdeenshire approach on this theme is based on the Kaizen model. Kaizen is a Japanese expression meaning making something as good as it can be and the process engages teams of employees in concentrated blitzes to identify more efficient ways of working. The exercise has been driven by Chief Executive Alan Campbell and his Senior Management Team since 2004, and is supported by facilitators in all of the council services and Kaizen Champion Pat Browne. For each blitz undertaken, a team leader is appointed and in turn selects a team of between 10 and 14 people who are close to the process to be improved. " ...

Via Aberdeenshire Council: Aberdeenshire Blitzes competition to take European award ...

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Automotive Manufacturing: Kaizen Methodology

Bentley manufacturing event will examine success through methods such as kaizen. ...

Bentley hosts manufacturing event

... "At Bentley on 18 October, manufacturing managers from across Britain will be examining how attaining high levels of production excellence by applying world class standards and techniques like Japanese-inspired kaizen methodology can lift the sector out of the doldrums. They will also have the opportunity to visit the Bentley production line. " ...

Via The Manufacturing Alliance: The exclusive network for senior management in engineering ...

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Thursday, September 28, 2006

Kaizen System: Perform to the Next Level ...

The lean kaizen approach to continuous improvement is just what the doctor ordered to enable an organization to achieve the next level of performance. Article discusses the successful formula applied by Toyota and other manufacturing companies, that can translate to organizations in other industries. ...

... "Based on Kaizen, which means continuous improvement, it is a systematic approach to identifying and eliminating waste. " ...

Via American Venture Magazine: When you are on the Plateau ...

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Friday, September 22, 2006

Kaizen Delivery Improvement Recognized by Toyota ...

Toyota recognizes the Hub Group for reducing its variability in on-time delivery. Hub's achievement in delivery improvement is celebrated by Toyota with its Kaizen Challenge Award. The two companies worked collaboratively to enable this accomplishment. ...

Toyota partner leverages kaizen process for successful on-time delivery performance ...

... "Hub Group, Inc. has been awarded Toyota's prestigious North American Parts Operations (NAPO) 2006 Kaizen Challenge Award. Kaizen is a critical component of the Toyota Production System (TPS) management practice, and this award recognizes Hub Group not only for its ability to work in partnership with Toyota management, but for significant performance and efficiency improvements achieved in product deliveries to Toyota's U.S. Parts Delivery Centers (PDCs) across the country.

The kaizen team, comprised of both Hub Group and Toyota professionals, was able to significantly reduce bunching (the tendency for inbound container volumes arriving at PDCs to fluctuate unevenly throughout the week), improve on-time performance (from not-late to not-late and not-early), and to reduce costs by eliminating rail detention and storage for the Toyota PDCs. As a result of the success of this initiative, additional Toyota PDCs have been added to the program. Since Kaizen is a continuing process, further improvements will be explored and documented throughout Toyota’s PDC system. " ...


Via Hub Group: Hub Group Earns Toyota 2006 Kaizen Challenge Award

Hub Group, Inc. is a leading asset-light freight transportation management company providing comprehensive intermodal, truckload brokerage and logistics services.

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Sunday, September 17, 2006

Kaizen Events: Employee Involvement ...

Metaldyne involves their workforce in continuous improvement through kaizen events. ...

Metaldyne uses Kaizen to drive continuous improvement ...

... "In addition, employees participated in 26 Kaizen group events in 2005 to improve all aspects of the operation. Another key driver was a preventative maintenance initiative in each department. " ...

Via Inside INdiana Business: Indiana Companies Honored For Productivity ...

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Kaizen Continuous Improvement Uses RFID in Manufacturing ...

Research indicates manufacturing companies leverage RFID technology to support continuous improvement methods, including streamlining their supply chains. ...

... "Topping the list is the trend toward lean manufacturing, a methodology that attempts to drive all waste out of manufacturing processes by employing such tactics as just-in-time inventory to ensure goods arrive for production when needed rather than ending up as inventory. " ...

Via RFID Journal: Forecast Indicates Strong RFID Demand by Heavy Manufacturing ...

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Thursday, September 14, 2006

Lean Kaizen: Team Drives Improvements ...

Kiesler Enterprises, a high-end custom cabinetry manufacturer, uses lean techniques to optimize performance for high growth and efficiency. ...

... "We also conducted Kaizens, short bursts of activity that result in significant improvements with the team. The Kaizen process helped redefine the relationship and interaction between sales and drafting. Both departments now combine resources and steps, said Joseph Murcko, project manager for the Arizona MEP. " ...

Via Yahoo: Custom Cabinetry Company Builds with Lean ...

The Arizona MEP is an affiliate of the National Institute of Standards and Technology (NIST) under the U.S. Department of Commerce. The national MEP is a network of manufacturing extension centers that provide business and technical assistance to smaller manufacturers in all 50 states, the District of Columbia and Puerto Rico. Through MEP, manufacturers have access to more than 2000 manufacturing and business coaches whose job is to help firms make changes that lead to greater productivity, increased profits, and enhanced global competitiveness.

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Manufacturing Data: Kaizen Display ...

Magnatag display kiosk provides kaizen manufacturing information ...

Kaizen on display ...

... "We use it for health and safety, productivity, quality, and Kaizen information, says the manufacturing administrator at a Texas chemical plant. " ...

Via Control Engineering: Display puts information where it needs to be ...

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Lean Culture Gaining Momentum ...

Survey of quality programs shows preference for lean manufacturing model. ...

... "When asked to specify the productivity/quality improvement programme currently being used, surveyed manufacturers in the UK and US put lean at the top of their list; the Germans and Mexicans preferred ISO certification, while Brazilian manufacturers gave their biggest vote to kaizen. " ...

Via The Manufacturer: Western nations thrive on lean manufacturing ...

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Kaizen: Sony Toyota Quality Problems

Revered for their kaizen quality programs, Toyota and Sony suffer from quality problems ...

... "For a time, American and European executives flocked here to learn Japanese quality-control concepts like kaizen, or improvement. " ...

Via International Herald Tribune: Recalls by Toyota and Sony shock Japan's pride ...

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Sunday, September 10, 2006

Kaizen Events: Early 5S Wins Sustain Momentum in Lean Journey ...

The lean implementation is valuable in the long run, however, early successes through kaizen events and 5S work delivers short-term gains that sustain the journey. ...

... "Almost always, there are immediate returns from the preliminary 5S process of getting every area shipshape. The same goes for early kaizen events that overhaul barnacled processes. " ...

Via Milwaukee Journal-Sentinel: Going lean brings long-term payoffs

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Kaizen Teian: Philippine Workers Slow to Adopt ...

Philippine workers slow to adopt kaizen techniques that value workers ideas to further continuous improvement. ...

... "Kaizen teian (employee suggestion) is very much a designated favorite mental sport in every Japanese corporation. " ...

Via ABS-CBN: Why can't managers get the best employee ideas?

Kaizen teian: "Kaizen Teian suggestions are usually small-scale ones, in the worker's own area, and are easy and cheap to implement. Key points are that the rewards given are small, and implementation is rapid ... "

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Monday, September 04, 2006

Kaizen Ethos: Wagamama

Kaizen ethos pervades Wagamama ...

Japanese Kaizen Philosophy used at Wagamama ...

... "Wagamama was founded in 1992 by Alan Yau, a former McDonald's franchisee in Hong Kong who used kaizen — the Japanese ethos of continual improvement — as his guiding philosophy. " ...

Via Times: Wagamama to go it alone in Boston ...

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Saturday, August 19, 2006

Toyota Kaizen Cultural Strength ...

Toyota's culture enables its kaizen success ...

Kaizen at Toyota is strengthened by its culture ...

... "Some of its strengths are cultural ones shared by the best Japanese companies. These include a respect for lifelong learning that aids kaizen, or continuous improvement. In addition, a consensus management style, combined with a Confucian respect for hierarchy, allows the rapid implementation of decisions. " ...

Toyota Kaizen Cultural Strength: Via Autoweek: The Roots of Toyota's Strength ...

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Saturday, August 12, 2006

Kaizen Events Kanban Discipline Outperforms Expectations ...

Investment VP sees company's kaizen experience as enabling expectations to be outperformed. ...

Kaizen principles adopted at Breeze ...

... "Since our initial investment Breeze has obtained three new patents, centralized materials purchasing, instituted Kaizen events that have led to cost reductions and adopted Kanban disciplines to streamline inventory management, said American Capital Vice President Helen Yang. As a result, it has significantly reduced its leverage and impressively outperformed our expectations. This quick de-levering, coupled with the Company's attractive growth prospects and continued cost reductions have created conditions for a dividend recapitalization. American Capital first invested in Breeze in August 2004, supporting Wind Point's acquisition. Founded in 1948 in Saltsburg, Pennsylvania, Breeze invented and patented the first worm-drive hose clamp, which uses a worm screw configuration to tighten, seal and connect pipes and tubes. " ...

Kaizen Events Kanban Discipline Outperforms Expectations: Via American Capital: American Capital Invests $52 Million in Portfolio Company Breeze Industrial Products Corporation

Breeze clamps uses kanban discipline to drive operational efficiency ...

Breeze Industrial Products Corporation with facilities in Saltsburg, Pennsylvania, Auburn Hills, Michigan and Frittlingen Germany, is a leading global supplier of proprietary and patented steel clamps for the heavy duty truck, automotive, and industrial markets. Offering 13 product lines for varied clamping applications, the Company sells approximately 13,000 different SKUs marketed under the Breeze, Torca, and Clamp-All brands.

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Thursday, August 03, 2006

Kaizen Blitz Momentum Builder

Navy accelerates momentum in AirSpeed lean practices through increase the volume of kaizen blitz events. ...

... "Q: How do we increase mass in AIRSpeed? A: Through kaizen blitz - multiple rapid improvements done by multiple participants simultaneously. " ...

Via Kaizen 10 in 10: building AIRSpeed momentum

AirSpeed kaizen reference ...

NAVAIR AIRSpeed Definitions: "Kaizen is a method for accelerating the pace of process improvement in any setting. It is typically a rapid (1 week or less) intense event where progress is made through all of the Define-Measure-Analyze-Improve-Control steps. This requires preparatory work completed on the Define step and even sometimes the Measure step by a small team led by a team leader and a Black Belt. The rest of the work is done by a full group where the participants work ONLY on the project and are relieved of responsibilities. "

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Saturday, July 22, 2006

Kaizen Visibility ...

... "The most impressive activity in the company is a strong participation in KAIZEN ... I could see many signs of this process by notes on the boards and travelers in the main meeting room, where activities are displayed. Everybody is aware of recent progresses and next targets. " ...

Kaizen Visibility: Via EMSNow: Dominique Numakura Newsletter from Japan ...

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Kaizen Passion: Ingredient for Manufacturing Excellence ...

You know you are on the path to excellence when the workforce exhibits these behaviors after a kaizen event ...

... "when empowered, fully-engaged machine operators extol the results of a recent kaizen event and cite the time and money they've saved the plant, the company and the customer. " ...

Via IndustryWeek : Editor's Page -- Building A Passion For Manufacturing Excellence

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Kaizen Implementation StockerYale ...

Kaizen implementation is undertaken by Stocker ...

... "The operating loss for the second quarter was $0.7 million versus $0.9 million in 2005, excluding stock-based compensation expense of $0.1 million and asset impairment charges in 2005 of $0.6 million, a 17% improvement. Research and development expenses of $0.7 million, were 3% lower than the second quarter of 2005. Selling expenses increased 24% to $0.6 million due to increased marketing and sales activities in the U.S. and Europe and FX impact in Canada. General and administrative expense rose 16% due to the expensing of stock based compensation resulting from the Company's adoption of FAS123R and consulting expenses related to Kaizen implementation in Montreal. " ...

Via StockerYale: StockerYale Announces Second Quarter 2006 Financial Results

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Kaizen Supply Chain ...

Supply chain successes discussed ...

... "Siemens changed the way it did business by adopting kaizen techniques and total quality management. This is a shining example of how changed supply chain methodologies can actually influence the bottom line and increase the company’s value. " ...

Supply Chains: Reinventions, Successes, and Failures ...

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Kaizen Accelerates Production ...

Kaizen quality initiative complements Christie's production acceleration. ...

Production accelerates as Christie keeps pace with kaizen quality ...

... "As part of its aggressive expansion in manufacturing capacity, Christie is also hiring additional technical and administrative staff that includes electronics, mechanical and optical engineers, technicians and industry experts. Christie has also implemented rigorous in-house educational and training programs designed to further maximize efficiency levels, streamline production, and deliver quality control standards that are among the highest in the industry. This includes an extensive global quality initiative and continuous improvements through Kaizen practices to ensure consistent conformance to customer expectations, while maintaining the highest standards of quality. " ...

Via Christie: Christie Ramps Up Projector Production as Digital Cinema Contracts Surge Worldwide ...

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