1. Lean Notes Page

3. Lean Notes What are the four things that need to get written on the reference edge ?_______ ______ ______ ______ This written information goes on the reference edge _______ it is cut. The _____ must check the measurements before the wood goes to the machines to get cut This information must be written in the ________ place by the worker. The _____ is assigned to figure out correct place (Problem solving) The information will be _______ where the lumber does not get cut. Reference Edge

4. The smooth edge of the board is know as the _________ _________. All __________ are referenced off of this edge with a square. The power tools use this as a reference also. The ______ _______ must always be cleaned so the cut will be straight. The ___ needs to be touching the fence 100 %. No separation. Use the ____ _____ to make sure you have accurate cuts. No wood should be cut without them unless your cutting ____ off the end to get the board square _______ _____ – a very serious grip on the wood so it does not move when your making the cut 3 Friends 1. _________ 2. _________ 3. _________

5. T______ Lean Evaluation Process Lean Process 0-100% What does the PM evaluate?_____________________________________________ Examples: Flow, Quality, Communications, Safety, Work Ethic A______ Lean Process 0-100% D______ Lean Process 0-100% B______ Lean Process 0-100%

6. QC must stay _____ by watching the cups for changing colors – so the product flow is at 100% __________ are responsible for changing the cups when they have no work or starting to run out of work The Job of QC is a develop an organized __________ plan – QC may not _____, sit, hold, get tools out, cut etc. QC ______ ahead time what your workers will be doing so that have plenty of work to do. The only time the workers will be on ____ time will be when the last piece of product is done. Having 2 to 3 workers doing the same task is not a _____ flow. Most times 2 out of the 3 workers will just be watching and less productivity will happen Workers lose ___ $ and QC lose ___ $ per minute after the red cup is up for longer than two minutes if productivity stops Red Cup = __________________________________________________ Yellow Cup = __________________________________________________ Blue Cup = ___________________________________________________

7. TRIM CELL LEAN PROCESS 1 Write multiple X’s on both sides of the lumber and label each side 2 Measure out the length that the blueprints shows (included in this packet) 3. Worker puts label (in the correct location) before it’s cut. This complete piece EFG must stay together during this entire process 4 QC checks length and signs it – then checks the process off on the lean charts 5 Jig saw or Handsaw rough cut to 36” 6 Goes to Band saw 24 to cut width 7 Goes to chop saw 27 to cut both ends 3/16” max to get reference edge (Follow Chop Saw process) 8 Goes to chop saw 26 to cut 45 degree corners 9 Router 14 puts biscuit slits in all corners. Mark with an X and keep same face down for this process 10.Dry Fit – check to make sure all corners are tight (no gaps), and flush from all angles – if not you may need to repeat one of these steps to make sure you did each process correctly. Usually, the biscuit router slits are not cut deep enough or the biscuit is not in the correct position in the slit Try sliding the biscuit down in the slit a little bit and the corner will get tighter. Watch the video on this process. 11. After QC checks the dry fit take apart and glue joint. The biscuit must be surrounded with glue, the router slit and inside faces of the wood to make a good tight joint. 12. Place a new biscuit over the glued in biscuit and trace around it. Make sure to do this on the top and bottom side. Take a pencil and place 4 dots on each biscuit on the bottom and two dots on the top. Be careful when you place the dots. Make sure that when you pound them in they are at least 3/16 of inch in from the edge of the biscuit. You do not want the biscuit to split out from the nail. On the Top two holes make sure the nails will not be seen once the body is glued on it. 13 Router 12 all edges once the trim is fully assembled. Hold carefully so trim does not break. 14 Finish sand, but hold carefully so trim does not break – very fragile 15. Make part of the assembly batch 16. Update Google Graph so that we have a current status on production

8. DIRECTIONS FOR LEAN CHARTS There is a graph in Google that must be kept up daily There is an abbreviation decode key in the lean packet Charts can not leave the classroom This chart lets the QC / PM know: - what the next process is - how much we are getting done - helps prevent bottlenecks and standstills - helps manage product flow - stops overproduction There are two lean charts to fill out. The first one is the (hard copy) packet which is very detailed and takes you through the process of completing each piece. The second is found on Google in the classroom folder. The Google lean chart will be viewed during the presentation of the production plan which is done daily. Its very important the Google chart is update before the start of the next production.

9. ***Never cut any boards that are not part of our product – Very Dangerous *** 1) Identify the correct saw – Look for the # and the letter on flip stop 2) Clean out the birds mouth but not with your hands – blow dust wood chips out 3) Put up the flip stops 4) Make sure X is against the fence 5) Cut off about 3/16 off each end to square board – write an X on the end of the board 6) Put the correct flip stop back down 7) Put X against the fence and one end (with X on against the correct flip stop) 8) Hold the board with a Kong Fu Grip 9) Keep your hands in the correct spots for safety (No closer than 6” from blade) 10) Bring saw down gradually (slow) and make your cut 11) Once the cut is made keep saw blade down and turn off 12) After blade has stopped bring the saw blade up 13) Slide the board down again to the flip stop and make your final cut CHOP SAW LEAN PROCESS

10. ***Never cut any boards that are not part of our product – Very Dangerous *** 1) Identify the correct saw – Look for the # and letter on Band saw fence 2) If blade guard is more than ¼” up from the wood tell Mr. Hopper 3) Clean out the birds mouth but not with your hand 4) Put X against the fence. 5) Keep your hands in the correct spots for safety (No closer than 6” from blade) 6) Hold the push stick handle at the furthest point out. 7) Push the wood against the fence (X against fence) with the left hand on the back end of the board and the push stick on the front edge. 8) Go forward. 9) Once, you get a half way through the cut switch positions with the push stick and your hand. At the very end of the cut move push stick out of the way of blade. 10) Turn off machine BAND SAW LEAN PROCESS

11. Lean Quiz Page