The Journey to Lean

A Journey into Lean Manufacturing

Kaizen foam is our new favourite thing!

Kaizen foam might not look like much but let me tell you, it is pretty amazing! It is such a simple and cost effective solution to keeping absolutely everything organised.  If you’re anything like me and naturally a bit messy, kaizen foam will transform you into a super organised machine!

Where have we used Kaizen Foam?

We have used kaizen foam in absolutely every area of our factory.

My desk, which was VERY cluttered, has now been sorted leaving only the essential items. These have been put into kaizen foam so that I haven’t got hundreds of pens (some of which probably didn’t even work!) rattling around in my drawer.  And I’m not searching for my post it notes that have slipped to the back behind the envelopes, which are hiding underneath my notebook… Now all admin tasks can be completed quickly and efficiently.

Kaizen foamIn the machine shop, every hand and turning tool has it’s set place in kaizen foam at each work station. This means that there is no more hunting through the drawers for the right tool.

 Kaizen foamEach tool is visible and easily identifiable and we can instantly see which tools are in use.  You can imagine how much quicker and easier this has made our machine set ups.


kaizen foamIn the assembly department, we’ve used it again for our tooling. We’d always spend a good 30 minutes to an hour on the first morning of tap assembly getting everything set up, including going around the workshop hunting down our hand tools before we could start- what a waste! (see The 8 Wastes of Lean).  The stations are now always set up and tools ready and waiting in kaizen foam.  That’s an extra hour we’ve gained to make even more taps!

kaizen foamWe have also used kaizen foam for making jigs to hold our products during assembly. This has been extremely useful as its very sturdy but doesn’t cause any damage.  It can also be adapted very easily.  For the same reasons, we also use the kaizen foam for storing parts ready to assemble.  There’s no fear of parts touching each other and causing marks.


As well as the practical benefits, kaizen foam makes everything look so much better. That might not initially seem all that important, but the whole team is now more productive from having an organised environment.  Our thoughts are not clouded by mess and it makes the working day much clearer and easier.

Happy manufacturing!

Rob, Nicola and the Team


The 8 Wastes of Lean- what does that mean?


What is continuous improvement and why is it so important?


  1. Heidi Hobday

    I love it!!! I def need some of this for my desk at work and home!!
    It’s looks great too. Genius! And it’s saving you so much tone. An hour is unbelievable, well done to you!

    • nicola

      Heidi it really is so simple to use and has completely transformed how our workshop looks! We’d love to see some pictures if you do manage to use some!

    • nicola

      And of course give us a shout if you need any advice!

  2. Wow, incredible weblog layout! How long have you ever
    been running a blog for? you make blogging glance easy.
    The total glance of your website is fantastic, let alone the content!

    • nicola

      Fantastic to hear that you have been enjoying the blog Julian! We are very new and only launched the blog last week! Please share and subscribe for more updates from us! Many thanks, the Journey to Lean team

  3. I am ssure his post hass touched aall the internedt visitors, itts eally rreally fastijdious artjcle onn bulding uup neew webpage.
    I’ve beeen browsng online morde thn theee hurs today, yett I
    never discovvered anny interestin artixle like yours. It is prtty wortyh sucficient forr me.

    In my opinion, if alll web owners and blogygers maqde goodd content matesrial ass youu did, the internet ill
    probably bbe a loot morte useful than ever
    before. I truly ove yur site.. Veery nicee colorrs & theme.

    Didd youu mzke this sitge yourself? Pleease reeply ack ass I’m attewmpting tto create my veey
    oown ste andd would love to lrarn whdre you gott tbis froom or exatly wjat thhe thheme iss called.
    Thak you!

    • nicola

      Hi Jona, pleased that you are enjoying the blog so far! I created this blog on wordpress, there are tonnes of themes to choose from. Good luck! From the Journey to Lean team

  4. Amazing blog! Do you have any helpful hints for aspiring writers?
    I’m hoping to styart my own site soon butt I’m a
    little lost on everything. Would youu suggest starting with a free
    platform like WordPress or go for a paid option? Thee are
    so many choices out there that I’m completely overwhelmed ..
    Any suggestions? Cheers!

    • nicola

      Thank you, we’re very glad to hear that you’re enjoying the blog! WordPress has worked very well for us so far. Good luck! The Journey to Lean team

  5. It’s difficult to find educated people about this subject, but
    you sound like you know what you’re talking about! Thanks

  6. This design is wicked! You certainly know how to keep a reader amused.
    Between your wit and your videos, I was
    almost moved to start my own blog (well, almost…HaHa!) Excellent
    job. I really loved what you had to say, and more than that, how you presented it.
    Too cool!

  7. I really enjoy your work. Excellent post.

Leave a Reply to free htaccess password generator Cancel reply

Powered by WordPress & Theme by Anders Norén

Pin It on Pinterest

Share This