Category Archives: lean manufacturing

“WITH” — Why is this here?

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I don’t have the name of the originator of this acronym. Why Is This Here? – “WITH”

As we continue the 5s + 1 journey, we find that it is not as easy as it sounds. Touring the manufacturing facility we continuously see items not in place, and in many cases not in place where they should be.

To get a feel for the process, start with your current area and surroundings. In my home office I notice piles of “Gonna-Do” projects forming. Seems like they start and stall. Look at the papers, folders, files, boxes or whatever and say: Why Is This Here? – “WITH”.

Look at just one item/project for a few minutes. Review what is in the pile, folder or box and throw away the truly non-essential items. Decide if it is really a goal contributing project, a nice to have project, or maybe a wishful non-critical project.

You will be amazed just sitting at your own desk, home or office and look what is out and waiting, or not needed. I know this thinking is not for everyone, but you will find out of place clutter in the oddest areas.

Walking around with this attitude helps keep momentum going especially if you are trying to 5s + 1 a manufacturing facility.  Getting started, doing and sustaining the 5s + 1 attitude is a difficult process.

  1. Sort 2. Straighten 3. Sweep/Shine 4. Standardize 5. Sustain +1 – Safety.

Remember:  Why Is This Here? – “WITH”

Good Luck on your Lean Journey — Once started you will find applications at work and at home.

Make 2018 your best year yet!

Customer satisfaction!

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Have you ever made one or more of your customers mad and didn’t even know it. Consider the following:

What is one of the worst things you can do to a customer — Cause opportunity for an RMA – Returned Material Authorization — something is wrong and the customer is not happy!

An RMA is the black mark of black marks.

I started my career of customer service in the world of RMA and Warranty.

It can be one of the most frustrating things you can do to a customer.

1.     The product was bought to use not send back.

2.     On-time, instant gratification, great product — gone.

3.     There is a tremendous need for a system, procedures, and people to handle the returns. 

4.     Both Sides are MAD – Customer returning product and the supplier trying to handle non-routine work.

From experience of owning a company I have witnessed the process of people in the organization knowingly shipping product, that was bad, to make the monthly numbers. 

When I discovered this several people were immediately removed from my organization. 

BUT

As I stopped and reflected on what happened, I decided I was probably part or all of the cause. 

I stopped cold — all managers were summoned and we decided this needed correction. Aanother moment of getting the Lean Journey started and not really being aware of it. The underlying cause was bad operating systems. We did not have good repeatable processes to ship material.

So began the journey. We did get better and improve. We began the real “Lean Journey”

I was amazed at the rate we lowered RMA’s at our company! — and — our growth took off.

 

Make 2018 your best year yet!

Comments welcome!

 

AS9100d – Aerospace Quality Management System / Lean Manufacturing!

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Have you ever thought about the “Lean Journey” and the process of having AS9100d – Aerospace Quality Management System?

I believe that obtaining the certification of AS9100d is a tremendous accomplishment for a small company.  As the required standards are reviewed and met you can find many parallels within and complimentary to “Lean Manufacturing”.

The basis of AS9100 accommodates and describes less waste, improved efficiency, less rejects, improved on-time delivery and standard processes and procedures.

In my previous company I believed in, recommended and achieved AS9100 certification.  Then about 10 years ago I really began to think through and build our company around lean manufacturing techniques. 

We recognized tremendous improvements — in all areas of our company!

I believe this is the way to go in the Aerospace Supplier Environment.  Too many times I’ve heard company presidents and owners say they couldn’t or wouldn’t get the AS9100 certification.  Too hard, Too much paperwork, my systems won’t accommodate the certification — Blah, Blah, Blah.

I am now affiliated with an Aerospace Machining and Fabrication company.  We have achieved AS9100d certification — We are expanding and growing with more “Lean Manufacturing Principles”.

Organized Chaos!

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I wrote about our move almost a year and a half ago.

Over the course of 8 working days we moved the office and machinery from 18,000 SqFt to 22,500 SqFt, with more expansion room available. The company is in a larger more modern facility, one building versus two.

We ran customer jobs right up until power was cut and the machines were moved out. From a delivery standpoint only one order went late. We opened Monday with our most critical machines operating.

The fundamentals of 5s and Lean begin. The shop is now set up for better more efficient operation. Is it perfect? No! When jumping on the “Continuous Improvement” train, it is never ending. We will be moving and tweaking forever.

We are looking forward to shaping our destiny and becoming a better company to operate, a better place to work, and a better supplier for our customers.

Then we were in “Organized Chaos” mode. Now we are better — still in somewhat “Organized Chaos” mode. Getting better every day!

Make 2018 your best year yet!

 

AS9100d / Lean Manufacturing / Efficiency / Bottom Line!

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AS9100d / Lean Manufacturing / Efficiency / Bottom Line!

I was introduced to one of the latest quality systems of the time in 1997. The Boeing quality system. We passed in December 1997 and never looked back.

I have always embraced the latest quality system available for the company.

Last month our company passed and moved from AS9100c to AS9100d quality system.

10 years ago I was introduced to “Lean Manufacturing” and after a bit of non-belief from employees, I made “Lean Manufacturing” a permanent part of my organization. Now in a new company I plan to again go completely into “Lean Manufacturing”. It can be done in a job shop. It definitely worked in my last company.

Couple the efficiency gains of “Lean Manufacturing” with the really good principles of the quality system AS9100d and really good things happen to the organization and the bottom line.

You can end up doing a whole lot more with a whole lot less. Our previous company went from $4 million in yearly sales with 90 employees to producing $15 million in yearly sales with 91 employees.

This stuff works — But — only if top management believes and works through the processes of quality and “Lean Manufacturing”.

Sounds almost too good to be true. I lived it. It works. Let me know your thoughts, and/or, contact me with questions.

Remember it is time to get ready for 2018. Get ready to make 2018 your best year yet!

 

Lean Manufacturing!

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I started on my Lean Journey in 2007. I joined a group of likeminded people wanting to improve Aerospace supply chain. After reading about Lean Manufacturing and hearing testimonials I took a complete leap into the world of Lean. I was producing approximately $10 million per year in sales, had good quality, very low (terrible) inventory turns with only reasonable on-time delivery.

I wanted my Company to be the best in class for our products. I hired two Lean managers, told one to start at the front end of our manufacturing process and the other to start at the end and eventually they would meet somewhere in the middle.

1st year I had no increase in costs. The lean initiatives paid for the two Lean managers. 2nd year my costs started dropping, profit improved and we began seeing improvement in quality and delivery. Inventory started dropping, inventory turns started an upward trend.

I was so naïve those years that I hadn’t realized I wasn’t even in the game for Lean — Yet. Gradually I began to see the benefit for my entire enterprise, from sales, order entry, engineering, and manufacturing through after delivery service.

Do you have a lean understanding or do you view it as a personnel and cost reduction opportunity?

Make 2017 your best year yet!