The Short Answer
Kaizen means continuous improvement: making small, steady changes that add up to a better process. In March 2024, we put kaizen to work in our Idaho shop with a new kitting system, kanban cards, one-piece flow assembly, a modular maker pipe inventory setup, and custom software to track every build. The result is faster, more accurate assembly of the gear on your belt.
Here's a look at each change, using our MagMaster Pro as the example.
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In This Guide
Watch: Shop Kaizen, March 2024
What Is Kaizen?
At Holstery, continuous improvement is at the core of how we work. "Kaizen" is a Japanese term for it. In manufacturing, and in plenty of other fields, kaizen means focusing on small, incremental improvements that make a process more efficient over time.
Instead of waiting for one big overhaul, we look for something to improve every day. Small changes are easier to test, easier to undo, and they add up fast.
Kitting: Getting Every Part Ready Before Assembly
Our newest change is a system called kitting. It starts in what we call the "inbox area," where empty bins from our shipping department are collected. For now, the bins are arranged with temporary tape to mark priorities while we fine-tune the system.
The goal is simple: handle incoming orders so every product is assembled with precision and speed.
Kanban cards tell us what goes in each kit
Each kit uses a kanban, a signal card that lists the exact components the kit needs. Our kitting station workers use it to pick the right parts from inventory, load them into the bin, and send the bin on to assembly.
Example: How a MagMaster Pro Gets Built
Here's kitting in action on the MagMaster Pro. Every component, from the packaging to the magnets and clips, is organized in the kit and ready before assembly starts. That keeps production moving and makes sure each MagMaster Pro meets our quality standards.
One-Piece Flow Assembly
A central part of how we build is "one-piece flow." Instead of building big batches, each piece is processed individually and passed along the line. That eliminates bottlenecks and keeps work moving.
You can see it in our assembly, where each part is riveted and assembled with care before it moves to the next step.
See more of how we build. Building Holstery in the USA →
Maker Pipe Inventory Storage
Improvement doesn't stop at the assembly line. We're experimenting with maker pipe to change how we store and reach our inventory. It's a modular, adaptable system, so materials are easy to reach and restock, and the production line keeps running without interruptions.
Custom Software to Track Every Build
We also built a custom computer program to track and validate the assembly process. It helps confirm every product is built correctly, and it gives us data we use to tighten up our production timeline.
Kaizen Terms at a Glance
| Term | What It Means | How We Use It |
|---|---|---|
| Kaizen | Continuous improvement through small changes | Every part of the shop is always up for review |
| Kitting | Gathering every part a product needs before assembly | Bins from the inbox area get loaded for each order |
| Kanban | A signal card that lists what's needed | Tells the kitting station what goes in each bin |
| One-piece flow | Building one piece at a time instead of in batches | Each part is riveted and assembled, then moves on |
| Maker pipe | A modular framing system | Adaptable inventory storage that's easy to restock |
What It Means for Your Gear
- Accurate orders. Kanban cards and kitting help get the right parts into every build.
- Consistent quality. One-piece flow and assembly tracking catch problems early.
- Faster improvements. Small daily changes mean better gear sooner.
- Built and backed here. Every Holstery product is assembled in our Idaho shop and covered by a lifetime repair or replace guarantee.
Gear Built on This Line
A few of the products that come through our kitting and assembly line.
MagMaster Pro
Our kitting example: an N52 magnet on an aluminum backer and steel clip.
Shop now →MagMaster
The same N52 magnet on a polymer backer and clip.
Shop now →DriverMaster Pro
Drill holster milled and assembled in our Idaho shop.
Shop now →TapeMaster Pro
Tape holster with a milled aluminum backer and spring steel clip.
Shop now →Our Pick: Holstery MagMaster Pro
MagMaster Pro | Magnetic Tool and Hardware Holder
An N52 magnet rated to hold 5+ lbs on an aluminum backer and steel clip. Kitted, assembled, and tracked one piece at a time in our Idaho shop.
- Assembled in Idaho, USA
- Lifetime repair or replace guarantee
- 45-day money back
- Free USA shipping over $99
$35
Shop the MagMaster Pro →Want the original? See the MagMaster →
FAQ
What is kaizen?
A Japanese term for continuous improvement: making small, incremental changes that improve a process over time.
What is kitting in manufacturing?
Gathering every part a product needs into one bin or kit before assembly starts, so the assembler has everything in hand.
What is a kanban?
A signal, often a card, that lists the parts or materials needed. We use kanban cards to tell our kitting station what goes in each kit.
What is one-piece flow?
Building and passing along one piece at a time instead of in large batches, which reduces bottlenecks.
Where are Holstery products made?
Every Holstery product is assembled in our shop in Idaho, USA.
Always Improving
In the spirit of kaizen, every part of our operation is under constant review, from kitting to final assembly to inventory. It's a journey that never really ends. It just keeps getting better with each small step.
