Leading a kaizen revolution

Going from 0 to 3,000 kaizens in less than a year

Format

Practitioner Presentation

Topic(s)

Highlights

Discover how your organization can implement an army of problem solvers and how to deploy kaizens for increase engagement and human development to take your lean journey to the next level. Hear how Alcon went from zero kaizens to over 3,000 by the end of the first year. See how the power of kaizen has evoked a desire for change and has accelerated improvements in 5S, quality, and performance, and how these operator-driven kaizens identified over $500K of cost savings.

Overview

Hear how Alcon's Houston site started its site-wide 'revolution' enabled through top-down leadership. Learn about the rollout, including lean training, coaching tactics, problem-solving A3 reporting and recognition. Gain insights into addressing obstacles systematically and achieving results. Discover valuable ideas to take away and implement in your organization including: Step-by-step case study photos going from current state to lean future state; comprehensive and innovative use of lean tools across multiple products and processes; effective custom lean material management and flow systems; leadership through benchmarking - partnering with other businesses on lean solutions; simple and powerful secrets – a mentor’s tip that will propel your lean journey.

Company

Alcon is the global leader in eye care, dedicated to helping people see brilliantly. With its 70-plus-year heritage, it is the largest eye care device company in the world – with complementary businesses in surgical and vision care. Being a truly global company, Alcon works in over 70 countries and serve patients in more than 140 countries. It has a long history of industry firsts, and each year commits a substantial amount in research and development to meet customer needs and patient demands. The Alcon Houston manufacturing site is a 24/7 day operation and has been on its lean journey for the last five years. www.alcon.com

Presenters: Jonathan Carter / Jasen Moffitt

Jonathan Carter is the operations director for Alcon, Houston. He began his lean six sigma career at 3M Company as a green belt, then as a dedicated black belt. He has also worked at companies such as Boston Scientific and Medtronic. Carter holds a bachelor’s degree in chemical engineering from the University of Iowa, and a master’s degree in strategic management from the University of Minnesota. He is a certified lean six sigma black belt and master black belt.

Jasen Moffitt is the operational excellence director for Alcon, Fort Worth. He began his lean six sigma journey 20 years ago while working for Rockwell Semiconductor. Since then, he has spent time in other lean six sigma pioneering companies including a Siemens/Motorola joint venture. Moffitt holds a bachelor’s degree in chemistry from the University of California at Irvine, is certified as a lean six sigma black belt and a project management professional. He a trained master black belt working on his certification requirements.