On 30 June, the first-ever Lean Boot Camp of its kind was launched at our German site – a format that has already proven successful at Texmo Blank locations in India and the USA. Four interdisciplinary Kaizen teams came together to identify and systematically address key production bottlenecks.
At the kick-off event, Managing Director Arjunan Ramachandran highlighted the significance of the initiative: "I see great motivation and energy in this group. With this format, we are creating a solid foundation for intensive learning, personal development, and tangible improvements – particularly in this week’s four Kaizen events, which focus on reducing scrap and increasing productivity."
Over the course of two and a half days, Arjunan personally accompanied and supported the teams on-site. The focus included measures to reduce scrap in both open and vacuum casting, along with initiatives to improve efficiency in the finishing department.
Initial improvements were implemented immediately, and the results speak for themselves. In testing, scrap rates for specific components were reduced by up to 6%. Additionally, two areas achieved a significant reduction in cycle times.
To conclude the week, a closing ceremony was held to recognise the teams’ efforts. Each team received a small trophy, while one particularly successful Kaizen team was presented with a special award – a testament to the team spirit and collective achievement displayed throughout the event.
“This week was a powerful reminder that collaboration and mutual support are the real drivers of meaningful change,” said Arjunan Ramachandran.
Looking ahead, it was announced that the Lean Boot Camp will become a regular fixture - a dedicated platform for continuous improvement, active engagement, and a shared commitment to change.
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Award for the four Kaizen teams – A moment of recognition at the prize ceremony:
