Case Study: Mohawk achieves a 25% productivity increase and improved employee engagement with KaiNexus

A Pilot and a Focus on Engagement: Continuous Improvement at Mohawk

Mohawk, North America's largest privately owned manufacturer of fine papers and envelopes, faced the challenge of scaling continuous improvement (CI) after a fast-growing envelope business, aging equipment, and the need to engage employees across multiple business processes. After a successful envelopes pilot (which delivered about a 25% productivity improvement with USC Consulting Group), Mohawk moved to institutionalize CI and sought a scalable tool to replace a homemade Microsoft Access tracker — engaging KaiNexus and its continuous improvement software to support that effort.

KaiNexus was implemented to capture, track, and close employee ideas and to drive engagement rather than immediately quantify ROI. Using KaiNexus, Mohawk logged 245 completed improvements, saved roughly 1,199 hours, achieved 92% system use and 98% logged-in engagement, and saw 90% of opportunities result in change with quality at 96% (satisfaction metric 136). The platform helped Mohawk scale CI across business processes, sustain employee-focused improvement, and replace ad-hoc tracking with a repeatable system from KaiNexus.

Mohawk

Ben Whitaker

Director, Business Process Management and IT