Great job Lynn and Brad describing that front end process, preparation, what you refer to as the hidden factory, and how it can be a companies constraint. The most intriguing part of this episode for me was when Lynn started talking about the gate between preparation and production, and how there might need to be a buffer there. In my 23 years of manufacturing, I found that to be absolutely true, and to be the very best way to protect my delivery dates. Gates are to keep things in AND to keep things out, so this gate between preparation and production, managed well, will keep the folks in preparation from releasing too soon, and the folks in production from snatching too soon. Even more helpful is it provides a little visibility for preparation as to what does “full kit” look like, and how do we know when full kit has been reached. Thanks for a very insightful topic that was approached from an incredibly relaxed solution based approach rather than revealing a mysterious problem that you can have the revealed solution only if you call BR549. Also, great job on the videography.
@@true32corporation thanks for the awesome comments. Ya we trying to help people as much as possible with real solutions that can make a difference today. Appreciate your support , so long as people are listening, we will keep producing
You need a totally open rectangular building with overhead bridge crane type hoists in major lift areas, you need convers,manual roller type to move parts from on operation to the next.employes should be trained to be able to move around as needed except maybe cabinet makers doing custom work,they should have their own area for the most part.do you people use the dowel pin type designs? Everyone should be able to communicate verbally to save time.open floor plan
I just noticed your shirt says no standard no kaizen. What does that mean as we do Kaizen events at my place of employment and nothing comes out of them.
Brad, This information is invaluable! I'm glad to see a fellow woodworker making these videos, bringing to light all the essential knowledge we need to be successful. This interview with Joseph is excellent-one of the best I've ever seen on the topic of creating standards. See you at IWF next week! A Ward Design
Great episode with a lot of great information.. except - 29:30 on allowing an employee to choose whether or not they participate (which is their choice) and waiting for them to “self select” out. If they don’t participate, it creates an exception to the rule and others will ask why you hold different standards/requirements for different people. I believe that will tear a team and culture apart especially if you are just starting to implement lean. They should participate or choose to leave. If they choose to not participate but want to stay then you have to have a conversation and tell them they need to go. You can’t allow them to stay and not participate in my opinion.
The description of the “line” was absolutely beautiful. Would love a B-roll of this set up, capturing the perfect world; showing people or stations supporting up and down the line. Absolutely brilliant, and motivating.
Very, very interesting, you are talking about melamine but call it TFL, no one calls it TFl but that's what it is!!!! I don't make melamine cabinets any more, I make cabinets from TFL.
Your absolutely right, people often misunderstand 1 piece flow. It is something to strive towards NOT something to be implement outright. That makes about as much sense as walking into the gym for the first time ever and immediately trying to bench press 1,000 pounds. Thank you for explaining and demonstrating these concepts in such detail. The transformation you helped them realize was fascinating. Thank you for sharing!
I am so pleased you two have produced this video it is just deep enough to touch the core of my business, it gave me focus and a deep sense on how to prioritize my business plan. Thank you both so much
I would be curious to load balance all the way back to cutting stiles and rails and door assembly in that time frame. Assuming you'd be running 5 pc doors. I would think two door clamps and a pendulum operation would get a lot closer to the robot performing all sanding operations. Plus, you could couple it with your edge sander.
This is very exciting my company does finishing and we have both manual and automated line. The finishing line might win but only by a small amount compared with a lean process. I will be overjoyed if the lean process wins though, even if it is a small time factor. Head not wallet is a spectacular way to live even with a finishing line. Something I always thought was we have to be careful that automation doesn't make us lazy or think we're done improving it.
Great comment ! Thank you. It will be fun and for sure we will all learn something! The Q&A will be a blast. Hope you cast ur vote at Stolbek.ca and sign up for webinar !
How are defects factored into the final score? If one system does it faster, but has a defect that would make it to the customer, how is that factored into the scoring?
ZERO DEFECTS ALLOWED. any amount of sand through would render that part no good. There is only 1 amount of acceptable defects - ZERO ! great question! I see most sanding solutions sanding through like crazy
Have you not watched all the recent podcasts? Why spread negativity while hiding behind an anonymous username? That’s like saying Paul’s channel would be better if he didn’t always promote his FastCap products. They are running business man. Where’s the free content you’re taking the time to create and share?
Sorry you feel that way. I don’t believe my Lean content promotes the robots, but they will appear in my videos as my content does come from my factory. (Where we use robots). But the message doesn’t change, you just have to identify the bottleneck in your operation and apply the lesson.
Those are the exact things I was needing to listen in this moment, just passed one entire Sunday to listen to it, because I was obliged to stop each 3 minutes to take notes and reflect how to implement those things in my company. Putting things in my todo list to discuss with the right people tomorrow, and preparing my action plan!
Lol 20 doors, it's like using a nuke to destroy a fly with a complete paint line, point of a paintline is to churn insane amounts of piece per hour with a minimal amount of employees. Ofc with 20 doors you can keep up with the paint line or even beat it with setup times/cleanings, now try doing 500+ doors in a single shift, you won't keep up with quality/efforts vs that kind of machines, even with a crazy setup like you have. Especially with your tiny doors, try doing those full high ceiling doors, you'll have a whole lot other kind of problems, Does that mean a paintline is a great investment ? Not sure ...
yes we get this comment. but not true. 20 doors or 2000 doors. imagine we are just tracking 1 order through the system. How long till it comes out the other end. so quantity doesn't change the out come. and to make it somewhat fair we did not include any set up or clean up times on the spray line. Quantity will not change the outcome whatsoever.
Right here, we will be posting the results soon. if you go to Stolbek.ca and vote for who you think will win. then we will update you along the way & you get a seat at the Q&A webinar at the end.
How do you manage the small amount of orders? I mean 5 pencil. Send an order to an office shop immediatelly? There will be an extra shipping cost. Or do you wait a bit for some similar products (pen, sharpie...) And bulk order with only 1 shipping cost?
Thanks for asking. there is no magic formula. just do what makes sense. in some instances with vendors that supply many items but have huge shipping costs. we collect the cards for about a week and place all the orders at once. or you can increase your purchase quantity until your happy with the shipping cost per item. but I would rather pay a bit more in shipping than hold extra inventory. But you are right in the case of pencils... I probably wouldn't order 5 at a time.
Typical, company doesn't want to invest in increased pay or benefits for workers but instead here's some bullshit team building crap no one wants to do.
