round 1 debrief - pm what worked? what didn’t work? – bottleneck at folding – bottleneck at...
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![Page 1: Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping](https://reader035.vdocuments.us/reader035/viewer/2022080915/56649d825503460f94a67c19/html5/thumbnails/1.jpg)
Round 1 Debrief - PM• What worked? What didn’t work?– Bottleneck at folding– Bottleneck at shipping and inspection– Inspection: sale height, stamping location, wild
stamping, uneven folding, scraping– Couldn’t meet sales for silver boats, glut of gold boats– Sales and production scheduling not matching– Inefficient material handling
![Page 2: Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping](https://reader035.vdocuments.us/reader035/viewer/2022080915/56649d825503460f94a67c19/html5/thumbnails/2.jpg)
Changes for Round 2• Consider the following:– Factory Layout
• Move folding tables together? And stamping?
– Point of Use Storage (POUS)• Get rid of kitting, move workers to folding, use POUS at fold1
– Poke-Yoke, Quality at the Source• Have folders inspect work?• Send rework only individual boats, not full batch• Inspection/rework before the oven
– Line Balancing• Inventory build-up detrimental to quality• Get rid of kitting, move workers to folding• Move workers around
![Page 3: Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping](https://reader035.vdocuments.us/reader035/viewer/2022080915/56649d825503460f94a67c19/html5/thumbnails/3.jpg)
Round 2 Debrief - PM• What worked? – Better factory layout– Boat quality down– Bad stamping – Need Poke-Yoke– Sail template worked well in inspection and folding
• What didn’t work or should be improved?– Inspection – move to source, self inspection– Not enough silver boats: orders not same as schedule
![Page 4: Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping](https://reader035.vdocuments.us/reader035/viewer/2022080915/56649d825503460f94a67c19/html5/thumbnails/4.jpg)
Changes for Round 3• Consider the following:– Factory Layout• Flex work
– Pull System, Kanban• Pull between station
– Continuous Flow and Supermarkets• Supermarkets around the oven (monument)
– 2 gold, 2 silver Kanban
• Continuous flow
– Poke-Yoke, Quality at the Source• Inspection at source
![Page 5: Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping](https://reader035.vdocuments.us/reader035/viewer/2022080915/56649d825503460f94a67c19/html5/thumbnails/5.jpg)
Round 3 Debrief - PM• What worked? What didn’t work?– Quick communication of demand– Let us respond to demand mix– Less stressful at each process– Might need Kanban adjustment – increase?– Flex workers – more balance– Less WIP
• Areas for improvement?– Larger Kanban– Time study in folding, line-balancing, flex working, work cell– Layout improvement– Another stamp tool? Another oven?