Lean Sensei International

David Koichi Chao is the president of a unique company called Lean Sensei International, which offers hands-on, specialized “coaching” to companies taking the Lean Journey toward world-class operation. He helps companies develop cutting edge strategy for becoming a lean organization, while delivering proven, highly effective lean methodologies.  Mr. Chao is an advisor to numerous organizations and companies world-wide, from local, family-owned businesses to Fortune 500 companies located in various parts of the world.

Mr. Chao specializes in providing lean strategy, lean thinking and supply chain performance improvement services to a broad range of corporate and public sector companies. As a professional engineer with extensive Canadian, U.S., and international industry experience, he has assisted numerous organizations achieve their goals. Mr. Chao is frequently represented in media as a columnist and industry specialist, with coverage in both local and major international newspapers & magazines.  In addition, he is a frequent speaker at various international lean conferences, including those hosted by both AME (Association for Manufacturing Excellence) and SME (Society of Manufacturing Engineers).  Mr. Chao’s workshop at the most recent AME Lean Conference received the highest ranking among all workshop speakers.

Mr. Chao’s very first appreciation of lean started when he began working for a Toyota Supplier in Japan, where he learned first hand the importance of quality and mistake proofing.  Soon after, he worked for Japan Airlines where he learned the significance of customer service and how lean works in a transactional/service environment.

Mr. Chao was one of the initial core team members that were responsible for bringing an authentic Japanese-derived Lean Manufacturing & Lean thinking principles to Canada from Japan.  As the first employee of GM/Suzuki joint venture operation in Ontario, he was instrumental in “North Americanizing” the Japanese-style lean programs and manufacturing philosophy when the word “lean” was still unknown. GM/Suzuki plant was the first “lean plant” in Canada and the most significant joint venture of its kind between a Japanese and Canadian manufacturer. 

Since the Suzuki joint venture, Mr. Chao worked as a consultant to Toyota and other Japanese companies, and were involved in numerous “milestone”  projects  including the setup of  Toyota’s CAPTIN aluminum wheel plant in Delta, BC.  Later on, Mr. Chao utilized his extensive lean experience and knowledge to become an advisor for various North American companies through CapGemini Ernst & Young, where he was one of the key leaders responsible for lean/supply chain projects.  He also held a position as the Managing Director of British Columbia Consortium for Manufacturing Excellence for several years, during which he worked closely with local companies to develop world-class lean strategy.  Mr. Chao became a “sensei” to companies in Jacksonville, Florida, as well, which formed the basis for creation of the largest and most successful lean consortium in North America. 

His extensive exposure to lean and his ability to quickly turn around an organization using Kaizen (continuous improvement) and Kaikaku (radical innovation) methods have earned him an undisputed reputation as a true Lean Sensei (Lean Coach). Because he focuses on making lasting changes through people and through teamwork, his work style is welcomed at the shopfloor level and appreciated by the management and senior executives.  Mr. Chao’s expertise in lean is not limited to manufacturing industries, as a result of strong involvement with non-manufacturing companies or service-oriented businesses.  This includes numerous projects with banking, healthcare, and other service-oriented firms. 

Mr. Chao was born and raised in Japan, and therefore fluent in Japanese. In addition to his work experience at Suzuki, Mr. Chao spent considerable amount of time working with other Japanese and North American companies, managing both small and large-scale projects. Some of the past and current clients/projects include: Johnson & Johnson, Weyerhaeuser, Sauder, United Airlines, Atsugi, Canadian Mint, CP Rail, Ballard, Avcorp, Kodak, Rolls Royce, Weyerhaeuser, FPI Industries, Sulzer Pumps, Hitachi, Takenaka, NuHeat, Nature’s Path, Neptune/ReadyFresh foods, Vancouver Coastal Health, Vancity, BC Gas, BC Hydro, BC Ferries, and many more.  Mr. Chao frequently visits Japan to tour benchmark companies and talk to their executives about lean strategy.

Considered by many to be an “authentic lean specialist” with true lean implementation experience, Mr. Chao has worked on over 800 projects over the past 22 years and has visited or worked with more than 100 plants around the world.  A recipient of seven scholarships from University of British Columbia, Mr. Chao ranked in the top 2% during his engineering program at UBC, and has been a registered Professional Engineer in both Ontario and British Columbia for close to 20 years.  Mr. Chao is a graduate of an Executive Certificate Program from Massachusetts Institute of Technology (MIT) Sloan School of Management.  He has also completed an Executive Education at Harvard Business School.  He belongs to several other associations such as Society of Manufacturing Engineers and Society of Automotive Engineers.  With a combination of hands-on lean and strategy experience, Mr. Chao has the capability to provide true project leadership and strategy assistance.

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