Custom Foam Systems

Hoshin Kanri Planning as a Template for Cultural Change
Hoshin planning as a vehicle to navigate the lean journey.

Custom Foam Systems had completed its first Kaizen initiative, and the shop floor was buzzing with enthusiasm on the positive change that had just been implemented. This coincided with the company’s annual strategic planning and as a leadership team, they recognized the need to update this annual strategic planning initiative to align and support the Lean journey they had started on the production floor.

During this session, participants will discover how through Hoshin Kanri (policy deployment) process, Custom Foam Systems’ mission, values and vision were defined along with their long range plan and goals.

The presentation will look at how activities are linked to Custom Foam's annual plan and deployed throughout all levels of the organization using A3 project plans or planning and review tables, including how the PDCA cycle comes to life with their regular review of each activity to establish where goals are not met, on an hourly, daily or weekly basis and therefore where improvement activities are focused.

Participants will learn how Hoshin has provided clarity, focus and accountability in all job functions, creating ownership for improving processes, to meet Custom Foam's customer’s demands.

Custom Foam Systems manufactures cost competitive engineered, fabricated and moulded polyurethane components to North American manufacturers who expect superior quality, exceptional service and on-time delivery. Their customers’ include industry leaders, from the furniture, electronics, appliance, recreational products, transportation and health care industries including Steelcase, Haworth, Krug, Teknion, Raymond, BRP, and Compx .

Custom Foam was founded by Tom Germann Sr. on the principle of providing innovative solutions for customers polyurethane foam needs. From 1973 to today they believe their company’s success stems from this principle, and that’s why they have used it as the foundation of their business planning for the future.

Bob Germann, President

Bob Germann was appointed as the second generation president and CEO of Custom Foam Systems in 2003. He previously held the position of VP Moulded Products. After working part-time and summers since he was 15, he started working full-time 1985 when he took on the challenge of starting up the company’s moulded products operation. He has since held positions as Moulded Production Manager and Engineering Manager.

Bob studied Chemistry (co-op) at the University of Waterloo prior to joining Custom Foam Systems. Since taking on the role as president and CEO, Bob has lead the company through the adoption of Lean Manufacturing principles and Hoshin planning practices. Bob resides in Kitchener with his wife and three children. He enjoys hockey and golf with his family and friends.