Time tracker Lean Manufacturing 7 deadly wastes Kaizen Value vs Nonvalue Intro to manufacturing Safety Boot Camp
A Typical Day… Production
Punching In First shift begins
7:50 am Workers punch in Start early Are the workers ready TIME TRACKER!! Work permit can not work without it!
7:50-7:54 am Wood Floater- getting lumber out to work stations Inventory Control- inventory count, plant layout and product distribution *All this happens during Plant Managers production plan delivery
7:54 am Plant Manager is the Boss! “Hands” Empower Plant Manager Delivers Production Plan PM’s produce all PowerPoints Daily Goals, Job charts, etc.
Plant Manager Responsibilities Production Plan Seating Charts Job Charts - QC placement - Worker placement Flow Process Charts -Need to know every step of the process -No bottle necks -No idle time Trains QCReview Production Plan Monitors QC Ensure a Quality Product Worker of the day Rewards QC Training Building Processes - QC needs to know all steps in great detail Monitoring Quality Worker Motivation Feedback on improvements Work uniform Punch In - fill in paycheck log
7:55-8:33 Inventory Control- Track product routing process with Bingo Charts Prevent overproduction Forecast/predict production deadlines
Keeps product organized in storage - no bottle necks - no standstills Checks off completed Processes - use bingo chart Feedback on improvements - what should we make more of Inventory Control Carries out job task set out by PM Training Process during lunch -communicate with PM Responsibility's Work uniform Lets PM know when enough pieces are produced - stop before we overproduce the amount we need Punch In - fill in paycheck log
7:55-8:33 Wood Floater- Product transportation Picked up and delivered from and to IC to QC BIG JOB!
Get product to correct job station on time - be fast and efficient at this job Never sit still always looks for product to transport Feedback on improvements Wood Floater Carries out job task set out by IC Training Process during lunch - work closely with IC Responsibility's Work uniform Have product ready before class starts - product should be at correct work stations - punch in when get to class - always check in with IC Punch In - fill in paycheck log
Starting Point Finishing Point WF PM QC W WW WW W Flow
Hour Work Stations Accountant QC CNC OS Safety Line Safety Line Safety Line WF Router Band Saw Disc Sanders Drill Press Plant Process Flow
7:55-8:33 Quality Control: Help carry out production Train workers Check product quality
Monitoring Quality Worker Motivation Feedback on improvements - no bottle necks - no standstills Quality Control Carries out job task set out by PM Training Process during lunch Responsibility's Work uniform Punch In - fill in paycheck log
Account Manager Payroll Accountability Bonuses Incentive tracking Deductions Accounting Pay Logs Time Cards Payroll Training Payroll Procedures Sick Days Employee reports (communicate with Plant manager) Punch In - fill in paycheck log
Account Managers Monday Handout new time cards Handout new pay log Print collection sheet Collect time card and pay log from last week Tuesday/Wednesday Collect forgotten time cards and pay logs Enter account information into spread sheet Thursday Print paychecks Friday Handout paychecks
Your Pay Workers $15/hour $600/week $2400/month $28,000/year Quality Control $22/hour $880/week $3,520/month $42,240/year Plant Manager $45/hour $1,800/week $7,200/month $86,400/year
7:55-8:33 am Waste Management- Recycle waste Sort “cut offs” and reclaim usable wood Communicate with Inventory Control and Plant manager-Making sure they use recycled waste FIRST.
7:55-8:33 am Production Workers
Actively listen to QC Feedback on improvements - how can we do this better Worker Work efficiently with quality - no bottle necks - no standstills Be Motivated - use red, blue, yellow cups Responsibility's Be able to measure Follow instructions Be to work on time Punch In - fill in paycheck log
7:55-8:33 am Clean-up Czar- Delegates the clean-up process Blows the work whistle “Cleeeeaaannuuppp!!”
PLANT MANAGER QC INVENTORY CONTROL Workers WOOD FLOATER WASTE MNGMT ACCOUNT MNGR RISK CONTROL (Safety) Workers Chain Of Command
LUNCH! Plant Manager Training
Collaboration Lunch Time: PM support group Between Schools Outsourcing/Globalization
PROBLEM SOLVING Material lists Math: Layout (math teacher teaches) Measurement Engineering Jigs and fixtures Design problems Production troubles: (video) Bottlenecks, standstills, etc.
Industry Partnership Mark Duginski- Donated machines Jig/fixtures (fences,etc) Accuracy/precision Interchangeable parts-Eli W., Henry F.
TEAM STUDY Over-time Production
Summary Student Driven!!!! Would you let your students drive your car with you in the back seat? Failure leads to success Not about the product it’s the PROCESS Not to make factory workers Life Skills- communication, team work, organization, people management, leadership/follower-ship, conflict resolution