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Contents | xi Formal Classroom Training . . . . . . . . . . . . . . . . . . 150 Voluntary Activities . . . . . . . . . . . . . . . . . . . . . . . . 150 The Identification of Potential Problems . . . . . . . . . . . 150 Hiyari Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Training in the Anticipation of Problems . . . . . . . 151 The Benefits of Kaizen at Toyota Astra Motor Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 CHAPTER 11 From Just- In- Time to Total Flow Management . 153 Just-In-Time at Aisin Seiki’s Anjo Plant . . . . . . . . . . . 154 Takt Time versus Cycle Time . . . . . . . . . . . . . . . . . . . . 156 Push Production versus Pull Production . . . . . . . . . . . 157 Establishing Production Flow . . . . . . . . . . . . . . . . . . . . 158 The Introduction of JIT at Aisin Seiki . . . . . . . . . . . . . 160 The First Step of Kaizen at Aisin Seiki . . . . . . . . . 161 The Second Step of Kaizen at Aisin Seiki . . . . . . . 162 Spreading the Benefits of JIT to Other Industries . . . 163 Total Flow Management. . . . . . . . . . . . . . . . . . . . . . . . . 164 TFM Transformation in Company A . . . . . . . . . . . . . . 167 CHAPTER 12 Just -In -Time at Wiremold . . . . . . . . . . . . . . . . . . . . 183 CHAPTER 13 The CEO’s Role in Kaizen . . . . . . . . . . . . . . . . . . . . . 195 CHAPTER 14 Going to the Gemba . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Gemba Kaizen and Overall Corporate Kaizen Two-Day Kaizen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Checklists as a Kaizen Tool . . . . . . . . . . . . . . . . . . . . . . 210 Gemba Kaizen Workshops . . . . . . . . . . . . . . . . . . . . . . . 211 Case Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Lessons from a 20-Year Kaizen Journey . . . . . . . . . . . . 219 Changing the IT Culture at Achmea . . . . . . . . . . . . . . . 225 Daily Kaizen at Tork Ledervin . . . . . . . . . . . . . . . . . . . . 229 Kaizen in Public Spaces: Transforming Rome’s Airports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
xii | Contents Sonae MC: The Silent Revolution . . . . . . . . . . . . . . . . . 239 Surpassing Expectations through Kaizen at Embraco . . 249 Kaizen at Oporto Hospital Centre: Making Patient-Centric Care A Reality . . . . . . . . . . 261 Kaizen Enables Innovation and Customer Intimacy at Densho Engineering . . . . . . . . . . . . . . . 269 Kaizen Enables Innovation and Customer Intimacy . . 273 Cutting Red Tape at a Public Utility: Enexis. . . . . . . . . 275 People Power: Participation Makes the Difference for Electrical Manufacturer in China . . . . . . . . . . . . 279 Rossimoda: Kaizen and Creative Product Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Finsa Uses Kaizen to Emerge Stronger from a Crisis . . 293 Innovating with Kaizen at Group Health . . . . . . . . . . . 301 Kaizen Helps Caetano Bus Deliver on Schedule. . . . . . 307 Kenyan Flour Producer Uses Kaizen to Increase Capacity, Improve Efficiency . . . . . . . . . . . . . . . . . . 313 Kaizen as the Foundation for Innovation at Medlog . . 317 Growing with Kaizen at Supremia. . . . . . . . . . . . . . . . . 323 Exceeding Customer Expectations at Walt Disney World . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Kaizen Experience at Alpargatas . . . . . . . . . . . . . . . . . . 335 Transforming a Corporate Culture: Excel’s Organization for Employee Empowerment . . . . . . 345 Quality in a Medical Context: Inoue Hospital . . . . . . 353 The Journey to Kaizen at Leyland Trucks . . . . . . . . . . 359 Tightening Logistics at Matarazzo . . . . . . . . . . . . . . . . 369 Stamping Out Muda at Sunclipse . . . . . . . . . . . . . . . . . 373 Housekeeping, Self- Discipline, and Standards: Tokai Shin ei Electronics . . . . . . . . . . . . . . . . . . . . . . 381 Solving Quality Problems in the Gemba: Safety at Tres Cruces . . . . . . . . . . . . . . . . . . . . . . . . . 389 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Worldwide Contact Information for Kaizen Institute Consulting Group . . . . . . . . . . . . 423
Page 2 and 3: Praise for Gemba Kaizen It’s exci
Page 4 and 5: Gemba Kaizen
Page 6 and 7: Gemba Kaizen A Commonsense Approach
Page 8 and 9: CONTENTS Preface . . . . . . . . .
Page 10 and 11: Contents | ix Seiton (Straighten) .
Page 14 and 15: PREFACE My two books, Kaizen: The K
Page 16 and 17: ▲ Standardization Preface | xv Ho
Page 18 and 19: ACKNOWLEDGMENTS The first edition o
Page 20 and 21: ABOUT KAIZEN INSTITUTE Founded by M
Page 22 and 23: Gemba Kaizen
Page 24 and 25: CHAPTER ONE An Introduction to Kaiz
Page 26 and 27: Major Kaizen Concepts | 3 ▲ Follo
Page 28 and 29: Act Check Improvement A P C D Figur
Page 30 and 31: Speak with Data Kaizen is a problem
Page 32 and 33: To realize the ideal JIT production
Page 34 and 35: The Ultimate Goal of Kaizen Strateg

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