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LEAN MANUFACTURING TECHNIQUES
FOR CUSTOM CABINET SHOPS
“Why you don’t need to learn Japanese to become Lean”
Lean is not as Complex as You May Think
Kan BanKaizenSix Sigma
Lean is not as Complex as You May Think
Kan BanKaizenSix Sigma
Custom Shop Lean
Lean is not as Complex as You May Think
Kan BanKaizenSix Sigma
Custom Shop Lean
Company Mindset, not “Rules”
Lean is not as Complex as You May Think
Kan BanKaizenSix Sigma
Custom Shop Lean
Company Mindset, not “Rules”
“How Can We Do This Better?”
“How Can We Do This Better?”
Every EmployeeEvery TaskEvery Day
Low Hanging Fruit- 5 S’s
Sort through each work station.
Low Hanging Fruit- 5 S’s
Sort through each work station.
Set things in order.
Low Hanging Fruit- 5 S’s
Sort through each work station.
Set things in order.
Shine and inspect.
Low Hanging Fruit- 5 S’s
Sort through each work station.
Set things in order.
Shine and inspect.
Standardize as much as practical.
Low Hanging Fruit- 5 S’s
Sort through each work station.
Set things in order.
Shine and inspect.
Standardize as much as practical.
Sustain through inspection.
JFP; A Case Study in Custom Shop Lean
JFP; A Case Study in Custom Shop Lean
A goal of 50% increase in production
JFP; A Case Study in Custom Shop Lean
A goal of 50% increase in production
Applying the 5S’s
JFP; A Case Study in Custom Shop Lean
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
JFP; A Case Study in Custom Shop Lean
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
Central Tool room – Work station storage
JFP; A Case Study in Custom Shop Lean
A goal of 50% increase in production
Applying the 5S’s
Low hanging fruit
Central Tool room – Work station storage
Repetitive task set-ups
Getting “Buy-In”
Change is frightening
Getting “Buy-In”
Change is frightening
Be honest and clear
Getting “Buy-In”
Change is frightening
Be honest and clear
Engage key team members
Getting “Buy-In”
Change is frightening
Be honest and clear
Engage key team members
Spread engagement to the entire staff
Review Existing Setup
Equipment condition
Review Existing Setup
Equipment condition
Operator training
Review Existing Setup
Equipment condition
Operator training
Floor plan
Review Existing Setup
Equipment condition
Operator training
Floor plan
Common tasks
Review Existing Setup
Equipment condition
Operator training
Floor plan
Common tasks
Follow the work flow
Follow the Work FlowNo More Tape Measures!
CNC programming changes
Follow the Work FlowNo More Tape Measures!
CNC programming changes
Standardize hardware and construction
Follow the Work FlowNo More Tape Measures!
CNC programming changes
Standardize hardware and construction
Assembly receives “kits”
Follow the Work FlowNo More Tape Measures!
CNC programming changes
Standardize hardware and construction
Assembly receives “kits”
Single unit batching
Single Unit Batching
Assembly begins immediately
Single Unit Batching
Assembly begins immediately
Errors detected very early
Single Unit Batching
Assembly begins immediately
Errors detected very early
Material handling drastically reduced
Single Unit Batching
Assembly begins immediately
Errors detected very early
Material handling drastically reduced
Maximize time flexibility
Put it on Wheels
Custom means being flexible
Put it on Wheels
Custom means being flexible
Fast changes
Put it on Wheels
Custom means being flexible
Fast changes
Machines as well as work stations
Take it to the Next Level
Constant review
Take it to the Next Level
Constant review
Use savings for capital equipment
Take it to the Next Level
Constant review
Use savings for capital equipment
Due diligence- will it work with your evolving system?
2 Way Communication
Feedback is needed to review changes
2 Way Communication
Feedback is needed to review changes
Honesty from top- down
2 Way Communication
Feedback is needed to review changes
Honesty from top- down
Build confidence and trust among the team
2 Way Communication
Feedback is needed to review changes
Honesty from top- down
Build confidence and trust among the team
Confident team members feed back accurately
2 Way Communication
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
Where to Find the Time
Delegate tasks to the team
Where to Find the Time
Delegate tasks to the team
Permission to “fail fast and cheap”
Where to Find the Time
Delegate tasks to the team
Permission to “fail fast and cheap”
Your office should be lean too
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?
Track Progress
Keep it Simple
Search out waste:
Wasted materials
Wasted money
Wasted time
Ralph Bagnallwww.consultingwoodworker.com
