Why Do Most Lean Manufacturing
Implementation Fail to Meet Expectations?
A while back, the Aberdeen Group, published their “Lean
Benchmark Report.” Of close to 300 manufacturers that participate in this study,
90% reported that they are committed to Lean. However, further analysis found
that less than 20% of these companies can be considered best-in-class. The report went on to say: "Companies that have achieved operational excellence through the deployment of a lean strategy share this important characteristic:
"Dedication to basics such as streamlining processes, creating
a well ordered work environment, and ongoing continuous improvement programs (Kaizen)."
Lean Manufacturing Transformation
It's BACK-TO- BASICS, friend!
Henry Ford: Creating the BASICS
Henry Ford first introduced manufacturing basics at his River Rouge operation in 1920. Using these basics as a basis for his production line concept, the Model T Ford plant was able to go from receipt of iron ore to casting the engine block, and to shipment of the machined engine block in a final assembled car in an astonishing forty-eight hours.
The Japanese used Ford's manufacturing basics, Juran's quality basics and Deming's management basics to create the foundation for achieving world class manufacturing commonly referred to as the Toyota Production System.
Vince Lombardi: Mastering the BASICS
Many years ago Vince Lombardi led the Green Bay Packers football
team to unprecedented success by having an almost obsessive
focus on doing the BASICS very well.
amazing how many individuals and companies have great visions
yet fail to achieve their full growth and earning potentials.
They're a lot like the Green Bay Packers' football team before
the arrival of Vince Lombardi... all the potential in the world
but with not enough focus on executing the BASICS of their business and profession.
In their efforts to draw closer to
customers, many manufacturers have lost focus on what should be a
company’s primary success factor –
mastering the basics of
their business and
Vince Lombardi, we need to have our manufacturing
teams identify and master the basics of manufacturing.
No lean manufacturing
transformation will meet
expectations without first
indentifying and then mastering Bill Gaw's 8-Basics of Lean Manufacturing.
If you've ever said, "There must be a better way."
... there is, and it's not more computerization!
you want to optimize your lean
transformation success? If so, you need to
identify and master the
lean manufacturing. Many historic, recurring day-to-day problems (perhaps the
same problems that plague your
operation) can be permanently
eliminated by a tenacious
execution of Bill Gaw's
"8-Basics of Kaizen Based Lean Manufacturing™."
Implementation Training via Bill
Training Tutorial: The
Kaizen Based Lean Manufacturing"
for eliminating part
reducing scrap and
* 8-Basics for
improving on time
for eliminating the EOM Scramble
for creating a fun working environment
for earning recognition and rewards
for reducing work place stress.
The 8-Basics of Kaizen Based
Kaizen Based Lean Manufacturing (KBLM) does not replace the MRP system but rather
its shop floor and purchasing sub-systems. KBLM methodology can generate two to three times MRP
cost reductions while producing significant improvement in
quality and customer
is a graphic that shows the impact of optimizing MRP shop floor and
purchasing sub-systems with Bill Gaw's KBLM methodology:
Manufacturing Knowledge and Know-How
Most training materials
Videos/Webinars that tell
you what to do but with very
optimization “know how.”
Videos/Webinars present their story
at a fast pace but most
viewer’s retention rate is
less than 25% and videos and
perform poorly as a
Bill Gaw's tutorials and training modules on the other hand include powerful, PowerPoint charts and graphics, "plus" annotated note pages with "slide commentary" and "lessons learned" by a "been there,
done that" operations professional. A value added, learning experience on "how to" design, implement and optimize a
lean manufacturing initiative
for individual and company success.
Our customers study the tutorial and T-modules content, print relevant sections, and highlight passages that are important to understanding and executing their change initiatives. The resultant blueprint is used for
training and empowering
their procurement team in their pursuit of inventory
and supply chain performance objectives. Videos/Webinars don’t provide the same
capabilities and their
performance results are
One of the keys to
success is having a great
coach. Whether you're in the
trenches or working your way up the
company ladder, the
experience of someone who's
"been there, done that" can
be invaluable. Throughout
his training material Bill Gaw
provides expert knowledge,
support, empathy, respect
and most important, the
he's always just an email
Another plus is that
every training library
manual should your
training objective be
An OEM company's Lean Manufacturing
Tutorial presents the Case Study:
"How the 8-Basics of Kaizen Based Lean Manufacturing helped Palomar
Systems eliminate their end-of-the-month scramble... Customer
satisfaction up from 85% to 99-plus%, Inventory
turns up from 2.2 to 8.3, product profit margin up
from 32% to 55%, scrap and rework reduce by 76%."
For more than 15 years, our 1700 plus customers and 15,000 plus newsletter subscribers have looked to Business Basics as a trusted developer of
lean manufacturing training material... manufacturing knowledge and implementation know-how that's helping individuals and companies exceed their goals and expectations.
Our customer list speaks for itself. These companies are serious, as we know you are, about optimizing their company results and improving their bottom line. To review a partial list of customers using Business Basics’ PowerPoint-Plus training in their pursuit of
best-in-class performance, simply click on
the "how to" that really counts!
Gaw's training is focused on the "how to." Unlike
material that tell you only what you need to do... Bill's training presents what you need to do and then
he shows you
how to do it.
T.J. Imholte, VP Integrated Systems
Advance Storage Products
"Bill is one of the most prolific individuals in the consulting industry and profession. He is a true thought leader and a great coach -- one of the best. His advice is golden and he has the respect of his colleagues worldwide. We all religiously read his articles and news-letters because they are informative, educational and right on the mark."
Business Development, Project Manager
The Lean Manufacturing, Back-to-Basics e-Library
Featuring Bill Gaw's, PowerPoint-Plus e-Tutorial:
"The 8-Basics of Kaizen Based Lean Manufacturing"
So much more than the competition
and at a very
46% discount for
new MMBP Subscribers
Much less than you would
imagine. To help you realize the full benefits of your
Lean Manufacturing, Back-to-Basics
we include the
The 8-Basics of Kaizen Based Lean Manufacturing
e-Tutorial (Price: $497.00)
Value Stream Mapping e-Module -
Value stream maps
help everyone agree on the current
state and what their future state
would look like. With this shared
vision, everyone begins to move
forward as a team and lean
Implementation exceeds all
Thinking Outside the Box e-Module
An e-Book... discover ideas, insights, and proactive solutions that create and
maintain a company's competitive edge.
Quality System Toolbox
an interactive ISO 9000 checklist and quality
manual and procedures to jump-start or re-ignite a company's quality management initiative. Provides a
quality management roadmap to optimize prior
quality efforts and maintain a focus on improving quality.
Train the Trainer Manual e-Module -
Should you decide to use your
in-house training we also
include a printed-version of an
methodology, a vital "train the trainer" resource.
A $816.00 value... discounted $320.00 for
Price of only:
Manufacturing, Back-to-Basics e-Library today at
your very special
holiday price of only $496.00 That's
a discount of
39% from our retail pricing
and thousands of dollars less than the price of attending
It is Better
With expert commentary and "lessons learned"
it's like attending a seminar in person, having Bill guide you personally through
his KBLM methodology.
Plus, you'll have all of
and lessons learned" for future reference and
provide the same
A Bill Gaw supporter saying it better than we can:
“Bill's experience and the resources he provides are first rate and of great practical value for both the experienced manager wishing to push improvement in their business as well as people at the beginning of their careers who need to understand the basics of making businesses lean and effective”
Quentin Kopp, a
Do you want to:
1. Become a better team member/leader/manager/executive?
2. Focus your energy on the significant issues?
3. Transform your work environment from drudgery to fun?
4. Minimize your day-to-day stress level?
5. Master the basics of lean manufacturing management?
6. Exceed your goals and expectations?
7. Gain recognition, promotions, and salary increases?
Does your company want to:
2. Optimize MRP/ERP and manufacturing processes?
3. Increase speed and improve quality?
4. Eliminate non-value-added costs?
5. Eliminate the high cost of overtime, scrap, and rework?
6. Improve customer on-time delivery of high quality products?
7. Gain control of inventories and optimize their turnover?
8. Increase team contribution to the company's "bottom line?"
Guarantee says it all
We are so sure that your
Lean Manufacturing, Back-to-Basics e-Library will have the impact
you desire that you can order entirely at our risk. The
training library comes with a No Risk, 100% Unconditional Money-Back Guarantee.
Believe this, we will never consider your purchase binding until you have reviewed all the material and put it into practice. We know that you, like our other customers, will be thrilled with the results. In fact, we are so convinced that your lean manufacturing training will work for you that if you're not completely satisfied for any reason at any time, simply let us know and we'll immediately refund your purchase price.
You simply can't lose.