Lean Case Study: Kaas Tailored

In this course, we visit upholstery solutions provider Kaas Tailored to get an up-close look at how they manage their high-mix low-volume production, promote kaizen, build management routines through gemba walks and daily accountability practices, and balance long-term hoshin plans with monthly experimentation. We also join a tour group as they learn about the seven types of waste and witness various flow simulations. Watch and be inspired by all the improvements the Kaas Tailored team has made so far on their lean journey.

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A Conversation with Jeff Kaas, President of Kaas Tailored

Gemba Academy Co-Founder Ron Pereira speaks to Jeff Kaas about the beginning of his lean journey, why his company is committed to teaching others, and what Day Camp is.

  • 2:06 Jeff’s beginnings with lean
  • 4:42 The tipping point
  • 6:04 Day Camp at Kaas Tailored

Speakers:

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  1. A Conversation with Jeff Kaas, President of Kaas Tailored07:51
  2. Kaas Tailored Tour Agenda03:44
  3. What to Expect on the Kaas Tailored Tour04:22
  4. The Gap Between Work and Hobbies18:02
  5. How Kaas Tailored Creates High Mix, Low-Volume Flow and Pull02:59
  6. Parts Kitting, Limited WIP, and Pull Signals at Kaas Tailored03:27
  7. The Ring Toss Visual Pull Signal at Kaas Tailored04:49
  8. One Piece Flow Cells at Kaas Tailored04:51
  9. How Long-Term Hoshin Objectives Turn Into Annual Goals and Small Experiments17:21
  10. The Visual Management System at Kaas Tailored09:18
  11. Periodic Review of Results and Improvement of the Hoshin Process07:25
  12. The Daily Gemba Walk at Kaas Tailored06:38
  13. Visual Management of Status for the Process, the Day, and the Year03:29
  14. Daily Accountability Through Team Training at Kaas Tailored05:08
  15. Observations About Daily Accountability Processes at Kaas Tailored08:33
  16. We Pushed Kaizen for 10 Years, Now We Pull Kaizen07:53
  17. A Problem Solving Example in Purchasing at Kaas Tailored16:31
  18. A Kaizen Example from Upholstery Process at Kaas Tailored10:39
  19. A Kaizen Example from Human Resources at Kaas Tailored11:11
  20. How Guiding Principles Engage People to Grow the Business and Themselves14:31
  21. How to Use the Kaas Tailored Kaizen Form05:53
  22. What's the Next Challenge for Kaas Tailored?21:01

Course Resources

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