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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How to Use the Kaas Tailored Kaizen Form

Tucker Kaas, Kaizen Consultant and GM Resident at Kaas Tailored, shares the kaizen form his company uses to eliminate waste.

  • 0:19 The problem statement
  • 1:12 Identifying wastes
  • 2:15 Root cause analysis
  • 2:50 Preventive action

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  1. A Conversation with Jeff Kaas, President of Kaas Tailored 07:51
  2. Kaas Tailored Tour Agenda 03:44
  3. What to Expect on the Kaas Tailored Tour 04:22
  4. The Gap Between Work and Hobbies 18:02
  5. How Kaas Tailored Creates High Mix, Low-Volume Flow and Pull 02:59
  6. Parts Kitting, Limited WIP, and Pull Signals at Kaas Tailored 03:27
  7. The Ring Toss Visual Pull Signal at Kaas Tailored 04:49
  8. One Piece Flow Cells at Kaas Tailored 04:51
  9. How Long-Term Hoshin Objectives Turn Into Annual Goals and Small Experiments 17:21
  10. The Visual Management System at Kaas Tailored 09:18
  11. Periodic Review of Results and Improvement of the Hoshin Process 07:25
  12. The Daily Gemba Walk at Kaas Tailored 06:38
  13. Visual Management of Status for the Process, the Day, and the Year 03:29
  14. Daily Accountability Through Team Training at Kaas Tailored 05:08
  15. Observations About Daily Accountability Processes at Kaas Tailored 08:33
  16. We Pushed Kaizen for 10 Years, Now We Pull Kaizen 07:53
  17. A Problem Solving Example in Purchasing at Kaas Tailored 16:31
  18. A Kaizen Example from Upholstery Process at Kaas Tailored 10:39
  19. A Kaizen Example from Human Resources at Kaas Tailored 11:11
  20. How Guiding Principles Engage People to Grow the Business and Themselves 14:31
  21. How to Use the Kaas Tailored Kaizen Form 05:53
  22. What's the Next Challenge for Kaas Tailored? 21:01

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