Transcript AGENDA
Making your Portable Restroom business Lean and mean – How to boost productivity and increase your bottom line AGENDA • What is Lean? • How can it transform your business? • How do you get started? • Common pitfalls and mistakes • Questions & comments WHAT IS LEAN? The term "lean" was coined to describe Toyota's business during the late 1980s by a research team headed by Jim Womack, Ph.D., at MIT's International Motor Vehicle Program. The research team found, upon studying Toyota and comparing them to the “Big 3” American auto manufacturers, that Toyota was able to produce MORE with LESS: MORE: • Quality • Value • Innovation • Customer satisfaction LESS: • Floor space • Inventory • People • Equipment • Defects • Accidents LEAN IS NOT… • About laying people off • A Japanese thing • Only for manufacturing • Only for large companies • A “program” • Only a set of tools CORE CONCEPTS OF LEAN PRODUCTION 1. WORK = VALUE ADD + WASTE Activities which meet the following criteria: • Customers are willing to pay for it • Changes the fit, form, or function of a product • Is done correctly the first time Everything else! • Increases cost • Lowers quality 2. RESPECT FOR PEOPLE • Engage the entire organization to eliminate waste Seven types of Waste Excess of Production Inventory Transport Unnecessary Process Defects Motion Waiting HOW CAN LEAN TRANSFORM YOUR BUSINESS • Increased customer satisfaction HOW CAN LEAN TRANSFORM YOUR BUSINESS • Increased employee satisfaction HOW CAN LEAN TRANSFORM YOUR BUSINESS • Increased productivity (labor and equipment) THREE COMPONENTS OF A SUCCESSFUL LEAN TRANSFORMATION • Culture • Operating system • Performance management system THERE ARE MANY LEAN “TOOLS” TO HELP IDENTIFY AND REMOVE WASTE • 5S – Workplace Organization • Single Piece Flow / Cellular Manufacturing • Visual Management • Total Productive Maintenance • SMED – Quick changeover from one product to another • Kanban / Pull Systems • Kaizen 5S IS A SYSTEM FOR WORKPLACE ORGANIZATION Sort Straighten Scrub Only the equipment, tools and material required for production is kept in the workplace “A place for everything, and everything it its place” Clean the entire workplace and all equipment Standardize Use standard procedures and checklists to maintain a clean and orderly work area Sustain Establish a system to monitor 5S to ensure that it is maintained RESTROOM ASSEMBLY KAIZEN Before: • Assemble 28 units at a time • 8 operators • ~60 minutes/unit assembly time After: • 3 teams of 3 operators assemble one unit at a time • 3 - 9 operators, depending on demand • ~45 minutes/unit assembly time (25% productivity improvement) RESOURCES Questions?