“Why you don’t need to learn Japanese to become Lean”
Kan Ban
Kaizen
Six Sigma
Kan Ban
Kaizen
Six Sigma
Custom Shop Lean
Kan Ban
Kaizen
Six Sigma
Custom Shop Lean
Company Mindset, not “Rules”
Kan Ban
Kaizen
Six Sigma
Custom Shop Lean
Company Mindset, not “Rules”
“How Can We Do This Better?”
Every Employee
Every Task
Every Day
Sort through each work station.
Sort through each work station.
Set things in order.
Sort through each work station.
Set things in order.
Shine and inspect.
Sort through each work station.
Set things in order.
Shine and inspect.
Standardize as much as practical.
Sort through each work station.
Set things in order.
Shine and inspect.
Standardize as much as practical.
Sustain through inspection.
A goal of 50% increase in production
A goal of 50% increase in production
Applying the 5S’s
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
Central Tool room – Work station storage
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
Central Tool room – Work station storage
Repetitive task set-ups
Change is frightening
Change is frightening
Be honest and clear
Change is frightening
Be honest and clear
Engage key team members
Change is frightening
Be honest and clear
Engage key team members
Spread engagement to the entire staff
Equipment condition
Equipment condition
Operator training
Equipment condition
Operator training
Floor plan
Equipment condition
Operator training
Floor plan
Common tasks
Equipment condition
Operator training
Floor plan
Common tasks
Follow the work flow
No More Tape Measures!
CNC programming changes
No More Tape Measures!
CNC programming changes
Standardize hardware and construction
No More Tape Measures!
CNC programming changes
Standardize hardware and construction
Assembly receives “kits”
No More Tape Measures!
CNC programming changes
Standardize hardware and construction
Assembly receives “kits”
Single unit batching
Assembly begins immediately
Assembly begins immediately
Errors detected very early
Assembly begins immediately
Errors detected very early
Material handling drastically reduced
Assembly begins immediately
Errors detected very early
Material handling drastically reduced
Maximize time flexibility
Custom means being flexible
Custom means being flexible
Fast changes
Custom means being flexible
Fast changes
Machines as well as work stations
Constant review
Constant review
Use savings for capital equipment
Constant review
Use savings for capital equipment
Due diligence- will it work with your evolving system?
Feedback is needed to review changes
Feedback is needed to review changes
Honesty from top- down
Feedback is needed to review changes
Honesty from top- down
Build confidence and trust among the team
Feedback is needed to review changes
Honesty from top- down
Build confidence and trust among the team
Confident team members feed back accurately
Feedback is needed to review changes
Honesty from top- down
Build confidence and trust among the team
Confident team members feed back accurately
Communicate with EVERYONE
Delegate tasks to the team
Delegate tasks to the team
Permission to “fail fast and cheap”
Delegate tasks to the team
Permission to “fail fast and cheap”
Your office should be lean too
Track Progress
1. What was prospected today?
2. What was conceptualized to move a project forward?
3. What was produced to move a project forward?
4. What was done that can be invoiced?
5. What distractions occurred today?
Keep it Simple
Search out waste:
Wasted materials
Wasted money
Wasted time
Ralph Bagnall
www.consultingwoodworker.com