Improving People Processes Speakers: Renee Held & Martin Kostecki, University of Nebraska Omaha, Nebraska Business Development Center

Transcription

1 Improving People Processes Speakers: Renee Held & Martin Kostecki, University of Nebraska Omaha, Nebraska Business Development Center Program handouts sponsored by: BCMC

2 Report Out Truss Craft Kaizen Event Martin Kostecki NBDC Renee Held NBDC Lewis Schelkopf Truss Craft Truss Craft-Hosted Value Stream Mapping Event

3 Kaizen Team Definition of Value Added vs. Non-Value Added Value Added Any activity that increases the market form or function of the product or service. (These are things the customer is willing to pay for.) Non-Value Added Any activity that does not add market form or function or is not necessary. (These activities should be eliminated, simplified, reduced, or integrated.)

4 Goal of Implementing Process Improvements OMIT What U DO Overproduction Motion Inventory Transportation Waiting Under-utilized People Defects Over-processing Individual Efficiency vs. System Efficiency 2X Speed

5 Perfect Linkage: Level Is demand leveled so that noise and unnecessary variation are removed from information flow? AND Is demand leveled from the most downstream process up the value stream and at each upstream process? Additional category ideas: Product/Service, Price, Place, Promotion, Physical Evidence, Productivity/ Quality, Surroundings, Suppliers, Systems, Skills, Safety; Maintenance, Methods, Technology

6 What causes stoppage of flow? Exercise: Form teams Complete team charter Assign team roles & responsibilities Assign Team Responsibilities Team Leader Team Information Station Layout & Spaghetti Diagram Time Keeper Recorder Observers Why Analyzers Role Description Keep team on Task; Develop Meeting Agenda Gather paperwork for Information Stations, Make sure all information is obtained Develop Target Area Layout & Map out Spaghetti Diagram, Obtain Movements of People and Materials Use stop watch to obtain elapsed times to calculate element times; Keep meeting on schedule Record all element descriptions & coordinate with Time Keeper element times; take minutes of meetings Record observations in target area Work with Observers to begin assessing need for each part of element content; Use assessments to streamline elements

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8 Ideas to Help You Observe! What items do the operator(s) use? What items didn t the operator(s) use? How is the area organized? Do the operator(s) seem confused by instructions? What difficulties do the operator(s) have? Are there standards available for the operator(s)? Do the operator(s) follow the work standards/checklists? How many tools are used? Are tools the same for all operators? What else did you OBSERVE? Truss Craft Supporting Data

9 Establish Customer Demand Rate Demand Rate: 8.93 board feet / minute GOAL: Produce to Demand

10 Spaghetti World Assembly Components Piece Parts Process Table / Jig 3 Spaghetti Diagram Layout A B C 2X Speed Follow Your Guy by drawing lines where he walks. If he stands in one place, make a Dot get bigger in that place.

11 Table / Jig 1 Spaghetti Diagram Layout B C A 2X Speed Follow Your Guy by drawing lines where he walks. If he stands in one place, make a Dot get bigger in that place. Day Shift : Figure out a test to separate the top cord from the bottom cords at the saw Figure out a test, try out and video tape a changed process in assembly where the top boards are placed, then the bottoms and lastly the webs to have everyone busy in value added from start to finish; carry more than one board if possible Day 1 Action Items Night Shift: Table Leaders: Train others on setting up the pucks for different positions; Lewis to view the videos from the outside cameras to evaluate delays to the inside conveyor line due to stoppage of flow in outside loading Night shift to let Lewis know on conveyor stoppage daily Josh: to check on why wedges are missing Lewis: talk with workers on dropping trusses Lewis & Leaders: figure out way for QC to know good vs bad Lewis: to talk with worker on behaviors

12 Day 1 Results: Tried out placing wood on separate carts for better placement at the assembly table Issues with saw uptime and unable to thoroughly test wood orientation on the carts Day shift overlapped with night shift for loading completed trusses; reduced stoppage of the conveyor and truss assembly Record breaking output from the assembly tables!! Day Two: Continued Focus on Team Problem Solving

13 Day Shift : Figure out a test to improve changeover time Keep breaks & lunch to designated times Continue to work on sorting at the saw Evaluate scheduling for order mix, i.e., big vs. small Evaluate design for opportunities at assembly Develop standard training for new employees Day 2 Action Items Night Shift: Create shadow board for tools & accountability of return Recommend workers use a tool belt Recognize need to measure placement of particular board spacing Evaluate a bungee cord system for the staple guns Identify available/open employee lockers for night shift use Continue to evaluate why wedges are still missing Determine why lift button not working properly on Table 1 Try out shift start up stand up status meetings Day 2 Results: Tested saw to assembly of saw carts not flipping boards, out the door quicker; not handling boards multiple times; Moved people to jobs they are better suited to perform; Showed assembly people in the yards, to better understand what needs to go right to avoid conveyor stoppages; Identified replacement parts for the assembly tables just need to schedule for fixing! Identified alternate suppliers for equipment servicing;

14 Day Shift : Continue to work on sorting at the saw; Evaluate scheduling for order mix, i.e., big vs. small; Deploy standard training for new employees; include video training; Schedule PM on the assembly tables; work on Identifying Predictive Maintenance too; Work with Saw vendors on existing problems; Document methods to eliminate tribal knowledge; Figure out standard clean up schedule at the saws; Day 3 Action Items Night Shift: Modify shadow board for tool placement & accountability of return Continue to evaluate why wedges are still missing; Consider having a shift transition person to improve communication; Both Shifts Identify methods to eliminate multiple boxes of the same plates being opened; Identify placement of carts, scrap lumber so people know how to return; Standardize stapling joints; Identify a list of fill in jobs for people to stay busy when down time; Place communication boards in different departments; Plus many more too numerous to list! Day 3 Results Slide 1 of 2 Saw operators have been fully trained in saw operation. Training manual to be put together for main items Technicians have been on site for each saw and went through complete check list and calibrations with operators Have done some of the calibrating of the jig tables more to come. Assembling training manuals for truss building, truss stacking and banding, and saw operation Have increased run time of saws to stay ahead of production Shadow boards in use throughout plant Plate inventory has been organized Stapling of joints is standardized throughout production areas Communication boards being installed

15 Day 3 Results Slide 2 of 2 More banding equipment stations on order Wedge/slider cutting refined working much better now Standardize truss construction techniques everyone needs to build in like sequence throughout plant to make cross training possible Training manuals and videos in use now getting refined List of Trusscraft Rules posted throughout plant and supplied to temp staffing agencies so new employees can follow rules/procedures Training videos and booklets to staffing agencies Weeks work hours posted by Wednesday noon so mall employees know work schedule Stand up meetings in use Let s Consider the Lowly Onion!

16 Alternate Problem Solving PO Lateral Thinking Productivity Truss Craft 0 Daily Output July 1 October Daily Output Linear (Daily Output) /1/2017 7/8/2017 7/15/2017 7/22/2017 7/29/2017 8/5/2017 8/12/2017 8/19/2017 8/26/2017 9/2/2017 9/9/2017 9/16/2017 9/23/2017 9/30/ /7/ /14/2017

17 Be Creative, Be Innovative. That is the only way to get an advantage. To do something different than the other guy. If you go along doing the same thing everybody else does, You ll never be any better than they are. 10/23/2017 Thank you to the Truss Craft team for their participation in this series of events! Colby Heuertz Javier Cabrera Darren Lamberson Duane Brumbaugh Todd Keber Josh Trotter Jason Casares Lewis Schelkopf Thanks to Jeff Taake for getting this started! session evaluations: bcmcshow.com/sessions

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