If you would like to “kick the tires” and give JobshopLean a try, I propose that you first host me for an initial 2-day visit. Prior to the visit, please complete this survey JobshopLean Assessment Tool and submit it to me. I propose the following tentative agenda for my fact-finding visit to assess the current state of operations in your facility:
- We will do the usual handshakes and mutual introductions to kick-off the visit.
- Your team will describe the issues that concern them that are the reason for the visit.
- I will make a brief presentation on JobshopLean.
- I will discuss with the team my conclusions based on the completed JobshopLean Assessment Tool that was sent to me.
- We will take a tour of your facility. During the tour, I will share my observations on different issues that I identify at different locations. You are welcome to videotape the entire tour since I will make several stops to point out and explain occurrences of the Seven Types of Waste. The video could then be used to educate your employees about Lean!
- After the tour, we will convene in the conference room where I will list all the ideas for potential projects that could be done to address all of the issues that must be addressed immediately.
- We will discuss the feasibility of hiring one or more graduate IE interns who will work under my supervision to execute the different projects.
- We will conclude the day with a Q&A.
Depending on my findings on Day 1 and the issues that you would like focus on, I will select a subset of activities for Day #2 from the following list:
- Fundamentals of Lean and Waste Elimination: I will show the video Toast Kaizen that introduces the Seven Types of Waste whose elimination is the foundation of Lean. I assure you that there is more than meets the eye in this video!
- Assessment of your Current Factory Layout:We will complete the Self-Assessment Tool to Evaluate any Factory Layoutto assess how much the existing factory layout enables Flow.
- 5S with a Purpose:We will go to any one department and brainstorm for ideas to free up wasted floor space that could be re-purposed for facility upgrades and expansion.
- Implementing the Quick-Start Approach for JobshopLean: I will present a case study on the implementation of this approach in a custom forge shop.
- Exercise on Factory Flow Analysis:
- On a CAD drawing of the existing factory layout, we will manually trace the routings of 10-15 individual components that are produced in high volumes to produce a multi-product Spaghetti Diagram. Next, we will analyze the Spaghetti Diagram for opportunities for facility re-layout to improve material flow.
- If the team is interested, we could analyze the timeline data in the ERP system for an order that was shipped for one of the components whose routing was traced on the CAD drawing. The timeline is bound to expose opportunities for reducing Lead Times by eliminating non-value added activities that are routinely being performed today!
- If the team is interested, we could take a guided tour through the facility and video tape the entire walk through. Then, back in the conference room, we will watch the video to identify and discuss reasons for occurrence of specific instances of the Seven Types of Waste.
- If the team is interested, I could give demonstration of (1) the Flow Assessment Tool (FAT) for rapid generation of Spaghetti Diagrams to visualize different changes in an existing factory layout, (2) the PFAST (Production Flow Analysis and Simplification Toolkit) software for material flow analysis in HMLV facilities and (3) the STORM software for design of an individual cell’s layout.
- Introduction to Value Stream Mapping: This presentation is a summary of the Learning To See book followed by a video of a VSM implementation at Jotul America.
- Exercise on Value Network Mapping:
- We will take your best-selling product and extract from its BOM only those parts and sub-assemblies that are manufactured in-house.
- We will map their routings on the current layout to produce a Spaghetti Diagram that depicts factory flow in the existing layout.
- We will analyze the Spaghetti Diagram for opportunities to improve the existing material flow and factory logistics.
- Exercise on Product Variety Mapping:We will try to develop a GT (Group Technology) coding system to classify your products and determine potential product families. For example, for one client, any machine part that they produced could be coded and classified using information on Size, Shape, Coating, Condition and Sealing. Using these features, a statistical model to estimate machining times for any part processed in their bottleneck department was developed.