Getting More than they Bargained for
We were conducting the first 5S Kaizen at the plant. With so much disorganization and clutter, it was affecting the team's changeover performance. When I introduced the concept of Spaghetti Diagrams, it opened their eyes to the possibilities and reduced the changeover time by more than 50%.
We were conducting the first 5S Kaizen at the plant. With so much disorganization and clutter, it was affecting the team's changeover performance. When I introduced the concept of Spaghetti Diagrams, it opened their eyes to the possibilities and reduced the changeover time by more than 50%.
Scripting Changeovers Leads to Consistent Performance
Once we added another layer of communication, performance improved.
Once we added another layer of communication, performance improved.
Even the Weather Couldn't Beat the Team
With an impending ice storm coming, would we get enough team members to test our new process?
From Tool Boxes to Tool Stations
By eliminating huge amounts of movement, the team cut the changeover time by almost 90%.
Let's see how things go
Standing by your convictions can lead to breakthrough performance.
Go See For Yourself
When we saw what was actually happening behind the paint booth during changeover, we were horrified.
Training in the Moment
During a changeover reduction Kaizen at a gummy vitamin factory, the team learned how to use “Tell, Show, and Do” to solidify the training for the crew.
There is One Best Way
Each technician thought their way was the best, until we actually measured their approach and results.
Overcoming Resistance to Change
The team was trying to get the crew to try their new changeover process. The crew wanted to do it their old way. Here’s how we got them to change their ways.
A Little Dab Will Do Ya
Putting a little oil between two washers kept the critical tooling from moving and shortened the effort to set up the line.
