1st Edition

Progressive Kaizen: The Key to Gaining a Global Competitive Advantage

By John W. Davis Copyright 2011
    220 Pages 26 B/W Illustrations
    by Productivity Press

    220 Pages
    by Productivity Press

    This book addresses how to make Kaizen a formidable competitive weapon. It serves as reinforcement for the key role the Lean coordinator holds in training and leading change that serves to make and keep a manufacturing firm world competitive.

    Examining the basics of an effective kaizen process
    Determining the general effectiveness of a Kaizen Initiative
    Developing a formal schedule for Kaizen
    Assigning a qualified full-time Coordinator
    Establishing a formal budget for Kaizen
    Number and type of Kaizen events conducted
    The scope of Kaizen training
    Communicating and tracking progress
    Overview of the various types of Kaizen
    High Impact Kaizen
    Training and Implementation Kaizen
    Problem Resolution Kaizen
    Sustaining Kaizen
    Key summation points
    Adressing key roles and supporting tactics
    The plant manager's role in Kaizen
    Characteristics of a highly Lean oriented plant manager
    Characteristics of Lean oriented company president
    The floor supervisor's role in Kaizen
    Insuring Kaizen as a tool for individual job improvement
    Value of a formal "WRAP" [Waste reduction activity process)
    Key summation points
    Avoiding the typical pitfalls
    Making the case against so-called "Expedited Kaizen"
    The misstep of not including salaried employees in the equation
    Allowing Kaizen accomplishments to deteriorate
    Failure to clearly communicate the intended scope of Kaizen
    Failure to effectively use a company's Production Engineers
    Failure to restructure the stated objectives of key players in the process
    The production manager
    The shop floor supervisor
    The production engineer
    The lack of proper reporting and effective communications
    The "Do's" and "Don'ts" of a viable Kaizen Process
    A simple exercise to getting the most out of any Kaizen event
    Key summation points
    Where to start and how to proceed
    The value of putting the first "Pull Production Zone" in Final Assembly
    Sticking to the plan and avoiding distractions
    Conducting the first High Impact Kaizen Event
    Getting the most out of "Training and Implementation Kaizen"
    Driving the use of "Problem Resolution" Kaizen
    Understanding the role and use of "Sustaining Kaizen"
    Implementing a WRAP - Waste Reduction Activity process
    Communicating and tracking results
    Key summation points
    Other key facets of getting the most out of kaizen
    Implementing and training Owner Operators
    Conducting an annual structured audit of Kaizen
    Selecting an outside service to assist
    Sharing results of the audit with the workforce
    Revising the Master Plan as needed
    Assuring Kaizen is used as a tool for individual job improvement
    Implementing a Kaizen incentive plan that works
    Establishing a Lean oriented Maintenance organization
    Ten Commandments of a fully supportive maintenance function
    Sharing gains with other firms and trade publications
    An eight Step Roadmap to making Kaizen all it can be
    Key summation points


    John W. Davis is an established author and recognized authority on Lean Manufacturing. With an extensive background in products ranging from air conditioning and fractional H.P, motors to jet engines, helicopters and elevators, Davis holds a broad range of experience in manufacturing and has consulted with numerous leading firms including Brunswick Corporation, Crane Pumps, CertainTeed Corporation, Rowe Manufacturing, JTB Furniture and Defiance Metal Products.