Hardwood Plywood; Achieving Quality with Organic Products Ken Durland Lean Manufacturing Manager Mt Baker Products
Mt Baker history n 10th Anniversary n Bought out of bankruptcy n Plywood Learning experience " Beginning reform is beginning revolution. " --Duke of Wellington
Donnie Allen
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
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
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
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
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
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
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
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
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
n Shop Rate September % n Shop Rate September % Did We Succeed? Almost all quality improvement comes via simplification of design, manufacturing, layout, processes, and procedures. -Tom Peters