Kaizen: The Devil is in the Details?

The Japanese concept of KAIZEN creating great cost savings for the manufacturing industry has put emphasis yet again on how simplicity is bliss.  One of the things that struck me in reading the Toyota article was reading the cliche: The devil is in the details.  Indeed? Knowing how to improve a workflow necessitates the need to know the nitty-gritty details of operations.  By doing so, one is given the right pair of eyes to look at things.  The article shared below tells of a very recent completion of a major overhaul at a manufacturing plant that gave emphasis on the benefits of lean manufacturing and making the best superior working environment for its employees.  It talks of extensive planning on the part of the Kaizen teams on how to build the best and most efficient facility.  The renovations gives testimony to the company’s commitment to adhere by lean manufacturing and continue having energy efficient operations that are environmentally-friendly.


But what is really Kaizen aiming at? Is it to say that details are the and-all and be-all of things?


Kaizen teaches us a new religion in philosophy -- knowing the devil in the details is not enough:  knowing the details that matter from those that don't DOES.  We need to know everything in order to know what to leave behind.  From knowing the difference, we are able to make the changes we need to make -- reduce a cycle time there, cut an unnecessary edge there.  A simple change may be a small difference, but when taken the extra mile together with all the other little changes, creates this ripple effect of efficiency chain that enables us to attain new effective ways to improve how we do business.  With renewed efficiency, life is made better for a lot of people  -- from the employee, to the satisfied customers. That being said, I say KAIZEN's applications is not limited to just the mechanics of lean manufacturing.  It is just the tip of the iceberg.

http://www.prweb.com/releases/plant/renovation/prweb9184348.htm

Midwest Precision Improves Manufacturing Efficiency with the Completion of a Major Plant Renovation

Midwest Precision LLC, a precision machining and assembly contract manufacturer, has just completed a major plant renovation project. The dramatic transformation of the facility provides a superior work environment for employees, additional manufacturing capacity, enhanced lean manufacturing, and environmentally-friendly, energy efficient building upgrades.

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Equipment upgrades and remodeling facilitate Midwest's lean manufacturing program

Our goal was to create a world-class manufacturing environment for our valued employees, exceed our customers' expectations and promote our continuous improvement culture.

Cleveland, Ohio (PRWEB) February 10, 2012

Midwest Precision has completed a major plant renovation as a key component of their commitment to lean manufacturing and creating a superior work environment. The completed project includes numerous equipment upgrades, an all-new machine tool and shop floor layout that reduces material travel distances, and facilitates the company's lean manufacturing program.

In October 2010, the new ownership team that acquired Midwest Precision also acquired the building and real estate with the intention of creating a showcase facility with expanded capacity and dedication to continuous improvement.

The completed renovation project spanned eight months and included a new energy efficient roof, installation of high-efficiency HVAC systems plant-wide, new lighting throughout, a fully re-surfaced floor and painting of the walls and ceilings.

“Our goal was to create a world-class manufacturing environment for our valued employees, exceed our customers' expectations and promote our continuous improvement culture” stated Wayne Foley, President of Midwest Precision. “Extensive planning went into the new layout that included input from nearly all our employees. Several Kaizen teams worked on lean manufacturing projects that were implemented into the new layout.”

The results are a dramatic transformation of the facility providing a superior work environment for our employees, a 25% - 30% expansion of manufacturing capacity, nearly 50% reduction in overall material travel distances, an 80% improvement in lighting and 30% reduction in energy costs. The renovations demonstrate the company’s commitment to lean manufacturing and creating environmentally friendly, energy efficient operations.

“Our objective is to be the premier, precision machining and assembly contract manufacturer in the world and we are taking the necessary steps to achieve that objective,” said Foley. “Continuous improvement and lean manufacturing are essential keys to that goal.”

About Midwest Precision
Established in 1953, Midwest Precision, formerly known as Midwest Screw Products, is an AS9100 / ISO 9001 certified manufacturer of precision machined components and assemblies for the Aerospace, Defense, Power Generation and Engineered Industrial markets. The company is well-known for its innovative manufacturing engineering, value-adding capabilities including program management and expertise in precision machining and assembly of close tolerance components made from Stainless Steel, Aluminum, Nickel Alloys, Titanium and other engineered materials.

Midwest Precision was formed by former executives of International Motion Control, a global leader in industrial and aerospace motion control components and systems. Midwest Precision applies operational expertise and investment discipline to successfully grow industrial manufacturing companies.