Kaizen Foam
Kaizen foam is layered foam that can be easily cut to fit tools or other pieces of equipment. It is very useful in The 5s System as it makes it very clear where items should go and what items are missing. It keeps them handy when it is needed.
How to Use it
Video Overview of Using Kaizen Foam
- Cut foam to fit inside of drawer.
Use the long Kaizen knife
- Put foam inside drawer
- Place tool on Kaizen foam.
- See if you can use the blowtorch method below first before cutting out the item
This will most likely create a better result than cutting items out, but requires you to find a metal object that you can heat up and plunge into the foam.
- Trace around tool using long nose marker.
Needs to be a black marker to make it cleaner.
- Label the space as you are planning.
If a tool is missing, you want to make it clear what is missing. You also want to make sure there will be room for labels.
- Use the utility knife to cut out the traced item.
It's okay if you go a bit too deep.
- Pull the foam out.
Use the plowing technique as shown in the video.
- Take the utility knife and fillet the top layer that was removed. Place this back inside the hole.
This only works with all black foam.
Alternate Cutting Methods
You may use a blow torch to heat up metal items and then push them into the foam to create different shapes. We have a few items to help you do this.
- 1" Copper Pipe - For making finger holes
- 3" Cup with Bolt - Large circular dishes
- Small Screwdriver - Fine adjustments
