Truth, Bit, Pull

Our Lean Philosophy

What is truth, bit, pull? It’s the Kaas Tailored way of explaining what we’ve learned from Kaizen, various lean tools, Lean Improvement, and the Toyota Way. 

In 1998, after an introduction from Boeing, Kaas Tailored began our journey with lean. We took its first group to Japan to tour a Toyota manufacturing facility and learn about lean manufacturing, “The Toyota Way,” and Kaizen.

As we started removing waste together, we began to see how the individual Kaizen tools replaced our bad habits with good ones. We’ve taken what we learned from Kaizen, Lean Improvement, and the Toyota Way and turned it into our own culture of continuous improvement.

Truth

Before we can change, we have to first understand that waste is a problem, then we have to decide we want to change. At Kaas Tailored, we know and show this truth by designing systems and processes that align with proven principles of success, reducing waste, which leads to joyful work and increased profit. 

This is why we’ve adopted a culture of continuous improvement. We use what we’ve learned from lean manufacturing and Kaizen, as we design our systems and processes to help us create a culture of continuous improvement. 

Bit

We’ve learned the value of producing in “bit,” rather than in “batch.” This allows us to be able to catch and correct defects as they arise instead of discovering them at the end of the process, which results in a lot of waste.

Bit is taking work and dividing it up into the little bits, as close to One-Piece Flow as possible. Examples include building one chair at a time, a face to face conversation, making one coffee drink at a time, and daily meetings.

Batch is when an operation is completed in a grouping all at once. The risk is that if there is one defect in the batch, there are likely more defects throughout the batch. Examples include building all 20 chair arms at once, writing a group email, and making a pot of coffee, and quarterly meetings.

Pull

We’ve learned the value of pulling from our clients rather than pushing onto them. This allows us to only build exactly what our customer wants when they want it. Using the concept of pull allows us to deliver high-quality solutions, at a lower cost and lead time than our competition. 

Pull is when the customer is at the center calling the shots. Examples of pull include signals telling the team when to work and when not to work, allowing no to be okay, or face to face conversation for feedback on a change you want to make. 

Push is when the supplier is in control. Examples include continuing to work even if the internal customer is not ready for work, not taking no for an answer, or an email recapping what changes you just made. 

Learn more about Truth, Bit, Pull 

If you’re interested in learning more about truth, bit, pull and our journey with continuous improvement we’d love to hear from you. 

We are a teaching factory. We choose to share what we’ve learned about Kaizen and other continuous improvement principles with other businesses and organizations through our Kaas Waste Tour which we host in our living, breathing manufacturing facility in Mukilteo, Washington.

At Kaas Tailored, we talk a lot about continuous improvement as a culture. We use words like One-Piece Flow and Kaizen which can feel confusing if you’re just starting your journey. We’ve put together a small series that explains how we think and talk about reducing waste within our company so that you can have the vocabulary to start identifying waste within your world. Then, we can work together to help you start your own journey of continuous improvement.