Lean manufacturing is a business operating system that maximizes customer value while minimizing waste. Lean thinking defines anything that does not add value for the customer as waste. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste. Lean manufacturing seeks this goal through waste elimination along entire value streams instead of just isolated points. The creation of new processes that require less human effort, less space, less capital, and less time. Lean thinking will improve the performance of any business in any industry.Your Lean Journey Starts Here.
Reduce Lead Times by 80% Reduce WIP by up to 90% Reduce Floor Space by 75% Improve Quality by 50%
Congratulations to the group of Lean Implementer students who’ve finished ISI’s 2014 Fall/Winter train-the-trainer course!
There were 29 attendees from Advanced Industrial Devices, American Airlines, American Gaming Systems, Centek, Charles Machine Works (Ditch Witch), CMP, Linde Processing, Nameplates USA, McElroy Manufacturing, and OSECO. During the course, students were required to conduct kaizen events at their companies. They held events on cellular flow, 5S, and pull systems as part of the course requirements. These opened up floor space and capacity while reducing WIP and FG’s levels.
The current classes are full, but the next course will be starting in July of 2015. Visit ISI’s Lean Implementer page for additional information and to see the benefits of Oklahoma’s most comprehensive Lean training program.
Dates are set for the next two Open Enrollment classes:
Tulsa: Classes will be held February 6 – May 8, 2015
OKC: Classes will be held February 27 – May 27, 2015
Please join us for a free Measurable Management Breakfast, and meet the program author!
Industrial Solutions – ISI is hosting a breakfast to introduce Robin Byrne, the author of Measurable Management.
Date: November 12th
Time: 8:00 am – 9:30 am
The Doubletree by Hilton at Warren Place, The Denver Room
6110 South Yale Avenue, Tulsa, OK 74136
Hurry, space is limited!
Industrial Solution’s Colin Reed presented a 75-minute breakout session on “Why Lean Doesn’t Work” at the 2014 Conference on Manufacturing, presented by the Oklahoma Manufacturing Alliance. Colin discussed why initiatives fail, and what leaders need to do to ensure they are successful. His presentation can be seen at: http://www.okalliance.com/2014/10/2014-oklahoma-conference-on-manufacturing-presentations/.
The Manufacturer’s Workshop the day before the 2014 Conference on Manufacturing was a huge success! ISI’s Colin Reed, Mark Bradway & Brian Hill hosted a fun, hands-on workshop with about 85 people attending. Over the 3-hours, nineteen teams of 3-5 people competed to “make” as much money producing paper stars as possible during three rounds of simulation.
They were also given a Challenge:
• Meet Customer Demand
• Create 1-piece flow
• Have cellular flow with balanced work
• Ship all Stars on time, in FIFO order
After the first round, the participants did a waste walk on their processes and redesigned their layouts. After the second round, they developed Operator Balance Charts, and set up a pull system on the paper star process.
The solution was open-ended, and each team improved the process in their own way. The competition was pretty fierce to win. Thanks to all who participated!
Industrial Solutions will hold a workshop and breakout session during the 2014 Conference on Manufacturing, presented by the Oklahoma Manufacturing Alliance.
Sept. 30th Industrial Solutions’ Colin Reed, Mark Bradway and Brian Hill will be running a 3-hour Manufacturer’s Workshop that will focus on waste identification, cellular flow and pull systems. It’s a fun, interactive session that will allow attendees a hands-on demonstration and use of lean tools to eliminate waste along with the lecture.
October 1st Industrial Solutions’ Mark Bradway will conduct one of the breakout sessions, entitled “Why Lean Manufacturing Doesn’t Work”. Less than 3% of companies that try lean are successful at truly implementing it throughout the entire organization. Mark will explore the cultural and leadership issues that can lead to failure of a lean initiative.
Drawing on real-world examples, discussions will focus on what leaders can do to make sure successful improvements continue past initial implementations.
It’s an important session for company leaders hoping to understand why Lean transformations typically fail to achieve their full potentials of 300-400% improvement. (This session will be repeated in the afternoon)
For more information and to register:
Congratulations to the latest group of Lean Implementer students who’ve just finished ISI’s 2014 Spring/Summer 5 month course!
44 students from Allied Motion, American Airlines, American Gaming Systems, Baker Hughes, Caseco, Centek, Charles Machine Works, CMP, Ditch Witch, John Crane, Kimray, Linde Processing, LynnCo Supply Chain, McElroy Manufacturing, Professional Image, and PT Couplings were awarded plaques for their completion of the course.
Students were required to conduct kaizen events at their company as part of the course. There were a variety of projects chosen, resulting in dramatic savings for their companies. Below is a small sample of student event summaries:
Cable Reel Pull System: Customer Lead Time: Before- 9 Weeks, After- 4 weeks 56% decrease ; Manufacturing Lead Time: Before- 10 days, After- 3 days. 70% decrease ; Part Travel Before – 4953’, After 1936’ 61% decrease
Tool Crib, Pre-set and Grind: Build Time: Before- 50 min., After- 15 min, 70% decrease ; Foot Travel: Before- 1437’, After- 250’. 83% decrease ; Process Steps Before – 128, After 51 60% decrease — Added 3640 hrs. of capacity, savings of $397,000 annually
International Export Process: NVA Time: Before- 420 min/job, After- 35 min/job, 92% decrease ; Job Processing Time: Before- 60 min., After- 46 min. 23% decrease
Machining Cellular Flow – EDM: Part Travel in Plant: Before- 3522’, After- 2000’, 43% decrease ; Order Lead Time: Before- 32.4 days., After- 1.6 days. 95% decrease
Great job by all students!
Students are asked at the end of the program, “What’s something you got out of the course?” Here’s some responses:
-“We reduced enough steps in the cell that the operators were concerned about getting enough daily steps on their pedometers for the Wellness Program.”
- “It was much more complicated than I thought it would be. I learned my previous experience was lacking.”
- “As a Buyer, it will help me clean up my processes with my group, and with my venders as well.”
- “I worked with lean experts in the past, but was never exposed to the concepts like in this class. I learned a lot from the different students in the class, and seeing how others worked a problem.”
- “I got a better understanding of the past two years, where we were doing lean, but I didn’t understand how it all went together. I am on the floor more now, to serve the operator.”
- “Even though I was exposed to lean when I was Six-Sigma & Lean coordinator at my previous company, I was still lacking in my understanding and knowledge of what tools to use.”
- “Confused at first, by the farther we got into it, the more it clicked. VSM was a very valuable tool, used to not like VSM, now I use it all the time.”
ISI’s Colin Reed will present Visual Scheduling at the Enterprise Excellence Group’s (www.leanok.org) meeting on Friday, May 2nd. The 50 minute talk will discuss how paperwork flow through an office and service environment can lead to delays and mistakes. He’ll talk about techniques that will make it visible, real-time and show the status of jobs, people, and materials.
Location: Francis Tuttle Technology Center, 7301 W Reno Ave, Room 1160B (enter the east door of the main building and go to the first door on your left).
Congratulations to the latest group of Lean Implementer students who’ve just finished ISI’s 2013 Summer/Fall 5 month course!
34 students from American Airlines, Charles Machine Works, Cookshack, Digital Designs, CMP, American Gaming Systems, ATC Drivetrain, LynnCo Supply Chain, Taylor Industries, Centek, Baker Hughes, Muncie Power Products, Southern Specialties & McElroy Manufacturing were awarded plaques for completion of the course.
The students were required to conduct kaizen events during the course’s duration, and the work done was phenomenal. Some example results were:
Controller Assembly: Build Time: Before- 105 min. After- 40 min. 62% decrease ; Space Used- 28% decrease
1 pc. Flow and Leveling of Powder Coat: WIP: Before- 46 hrs. After- 6 hrs. 78% decrease ; Lead Time: Before- 10 days After- 7 days 30% decrease
Poly Tank Cell: Cycle Time: Before- 6 min. After- 4 min. 33% decrease ; Part Travel: Before- 2,304 ft After- 602 ft 74% decrease ; Inventory: Before- 6 days After- 1.2 days 80% decrease
Great job by all!
Students were asked, “What’s something you got out of the course?”
- “Being able to collaborate with people with different backgrounds, with different companies. It made me look at my processes differently”
- “I finally understand how all the lean tools fit together, and it has made me better able to teach the process.”
- “I think lean naturally, but now I can apply it to many situations. This has been 5 months of a Swiss Army knife of tools to attack waste.”
- “It’s given me the confidence to run events. It’ll be rough at first, but now I know it will be OK.”
- “Inventory: I’d never seen the waste of time and money in inventory and parts before this class, now I get it. We have hundreds of thousands of dollars in material just sitting around.”
Congratulations to our latest Measurable Management Open class graduates! The group of 10 students had some great results from their projects, and are shown after their final project report out with their ISI Instructor, Mark Bradway.
One student said of his projects for the course:
“My first project was my new scheduling strategy that cut 14 days from the process time, and eliminated 56 jobs from W.I.P. The second was on process improvement in the door shop, utilizing one piece flow and yielded a labor savings of $350.00 per day.”
ISI Presents Toyota Kata at Manufacturing Conference
ISI’s Colin Reed presented Toyota Kata at a breakout session last week at the Oklahoma Conference on Manufacturing, put on by the OK Manufacturing Alliance. The session was an introduction and overview of the Toyota Kata methodology, based on the book Toyota Kata by Mike Rother.
The 75 minute session covered background, theory and definitions, PDCA cycles and what Kata programs look like. The presentation will soon be available at: http://www.okalliance.com/2013/10/2013-presentations-and-videos/
See how we can help your company learn and use this method to grow your people and improve your business.
The brochure for ISI’s Kata Introductory Training & Implementation Program can be found at: http://www.isiworld.net/toyota-kata/
ISI Client wins OK Governor’s Manufacturing Leadership Award
Yet another one of Industrial Solutions’ clients has won the OK Governor’s Manufacturing Leadership Award! The OK Manufacturing Alliance and Lt. Gov. Todd Lamb presented the award last week to Oklahoma City based CMP Corporation, a manufacturer and distributer of HVAC and refrigeration compressor parts.
ISI has guided CMP through a complete Lean Transformation of the business. Starting in March 2011, we helped management establish a new strategy of operational excellence based on Lean Thinking and the Toyota Production System. We then began detailed training of the CMP associates, helping them understand and implement the lean tools. It started with basic lean training, using the Lean 101 class, and value stream mapping.
ISI’s facilitation and consulting services guided them through the process, making ideas become reality. A set-up reduction and cellular flow project aligned multiple machines together to produce a product family within a cell. Other initiatives worked on material flow and waste reduction. Meanwhile, select associates were sent through ISI’s 200-hour Lean Implementer course, to become internal Lean Champions.
The company has made significant gains in it’s production processes. One example is the crankshaft value stream: its lead time was reduced from 85 days to just 10 days, and the average cost reduced by 25%.
The OK Alliance write up can soon be seen at http://www.okalliance.com/2013/10/2013-governors-manufacturing-leadership-awards/.
Classes now forming for Track 35 Lean Implementer.
Industrial Solution’s Colin Reed will be speaking on Toyota Kata at the Oklahoma Conference on Manufacturing, on October 9th. The Oklahoma Alliance for Manufacturing is sponsoring the event in Oklahoma City.
McElroy Manufacturing sees great benefits from Industrial Solutions’ led Kaizen Event.
(click to view article)
• All Lean Implementer classes are full! Our next classes will begin January 2014. Schedule coming soon.
• Spanish language classes are now available! For the following workshops:
Congratulations Recent Measurable Management & Lean Implementer Graduates!