2. Hardwood Plywood; Achieving Quality with Organic Products Ken Durland Lean Manufacturing Manager Mt Baker Products

3. Mt Baker history n 10th Anniversary n Bought out of bankruptcy n Plywood Learning experience " Beginning reform is beginning revolution. " --Duke of Wellington

4. Donnie Allen

5. Be willing to make decisions. That's the most important quality in a good leader. Don't fall victim to what I call the Ready- Aim-Aim-Aim Syndrome. You must be willing to fire. -T. Boone Pickens

6. Differences of Lumber and Hardwood Plywood n Grading vs. Inspection n Manufacturing Assembly n Manufactured Defects Learning is not compulsory... neither is survival. --W. Edwards Deming

7. How Do We Compete? n We make the finest hardwood plywood n Niche Markets n High Quality, High Mix - Low Volume u McDonald’s vs. Wendy’s It is not enough to do your best; you must know what to do, and THEN do your best --W. Edwards Deming

8. Quality Tools n JIT n Japanese Manufacturing Techniques n Upside Down Pyramid n Kaizen “We are being ruined by our best efforts” - W. Edwards Deming

9. Rule #1 n Quality Sells n Everyone Knows “Quality Sells” u The trick is doing what it takes n Build in Quality vs. Inspect in Quality First they ignore you, then they laugh at you, then they fight you, then you win. --Mahatma Gandhi

10. Lean Manufacturing n Minimum Input = Maximum Output u Find and eliminate the waste F Seven Deadly Wastes: Overproduction Inventory Defects Waiting Time Transportation Processing Motion “Companies will become lean for two reasons; either they are making money and see the opportunity, or they are losing money.” - Unknown

11. No Overproduction n Greatest waste of money and resources u Uses materials that may be needed for other orders u Involves extra handling, storage, and space u Hides other problems F Defects " Beginning reform is beginning revolution. " --Duke of Wellington

12. Reduce Inventory n Closely connected to overproduction u Obsolete panels u Long loading times u Quality problems u Scheduling problems " Planning is as natural to the process of success as its absence is to the process of failure. " -Robin Sieger

13. Eliminating Defects n Most effective with low inventory u Defects are seen at the next workstation F Action taken immediately and problem eliminated n Find the root cause u Don’t put on a band-aid “Without data, it’s just another opinion.” - Moshen Modarres Fathee, Boeing Corporation

14. n Shop Rate September 1999 - 8.8% n Shop Rate September 2003 - 2.32% Did We Succeed? Almost all quality improvement comes via simplification of design, manufacturing, layout, processes, and procedures. -Tom Peters