101 Kaizen Templates

21 Articles

101 Kaizen Templates: Changeover Analysis

By Jon Miller - February 7th, 2008

There are many common non-lean behaviors such as local optimization, batch work, and building up inventory. Creating WIP lengthens cycle time, worsens quality, builds up barriers between processes and people contributes to late deliver

101 Kaizen Templates: Takt Time Calculator

By Jon Miller - February 4th, 2008

A reader pointed out that the takt time for posting the 101 kaizen template has exceeded. It is true that we have not been hitting a consistent 1 template per 3.5 days. To meet our goal for 101 of these by the end of 2008 we will need

101 Kaizen Templates: ECRS Worksheet

By Jon Miller - January 25th, 2008

We often talk about lean management being the elimination of all waste and non-value added. We may call it the pursuit of perfection, of a waste-free process. But what if we can’t eliminate a certain waste from a process? What to

101 Kaizen Templates: Minor Motion Analysis

By Jon Miller - January 19th, 2008

We’re big fans of making significant organization-wide change by involving everyone in small improvement activities every day. This is especially important for sustainability as you progress on your lean journey. As you progress

101 Kaizen Templates: Safety Calendar

By Jon Miller - January 13th, 2008

Early in the year is a good time to refresh our commitment to health, safety and sustainability of our various enterprises. Despite our best intentions, habits being what they are, these resolutions are too often not so resolute. Unlik

101 Kaizen Templates: Stand in the Circle

By Jon Miller - January 9th, 2008

The 60-minute kaizen exercise we call “stand in the circle” originates in the teaching method Taiichi Ohno used. This involved a piece of chalk, a circle drawn on the concrete floor, and a manager left to stand in it for ho

101 Kaizen Templates: The Checklist

By Jon Miller - January 6th, 2008

This is the first post in the 101 kaizen templates series. Only 100 more kaizen templates to go. Takt time is 3.5 days per template. I considered planning out and structuring this series but for now we’ll just go with the flow an

101 Kaizen Templates

By Jon Miller - December 26th, 2007

January 2008 will mark 10 years Gemba Research has been in business. This blog has been active for just over four years now. We are reflecting on the past 10 years in an effort to renew our purpose and focus our energies. We will do th

Governor Vilsack Plans to Create Lean Manufacturing Institute in Iowa

By Jon Miller - January 15th, 2006

Governor Tom Vilsack has been at the forefront of his commitment to Lean government in Iowa. One example is the use of kaizen for the Air Quality Permit processingat the Iowa Department of Natural Resources. Another example of Lean gov

Mr. Toyota Goes to Washington

By Jon Miller - August 11th, 2005

The August 12, 2005 article in the Wall Street Journal titled “Toyota Lobbies to Avoid Blame Amid U.S. Auto Industry Woes” explains how Toyota is adding a sixth lobbyist in Washington D.C. in an effort to avoid being bashed

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