Shop Death by Waste! | Pierson Workholding Lean Training
ฝัง
- เผยแพร่เมื่อ 26 ก.ค. 2024
- Today we talk about shop death by waste and how to avoid that with lean training!
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Hopefully you caught part one where we talked about company culture and what makes Pierson Workholding a great place to work. Now, in this episode we’re going to talk about the eight wastes of lean, how there is waste EVERYWHERE, and how to eliminate it so we can work efficiently, happily, and go home on time!
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*Videos We Recommend*
Fixture Friday Series:
THIS is the playlist to watch if you want to learn about designing fixtures.
• How We Got 24 Parts on...
Shop Tour Series:
Tag along as Jay gives a tour of the shop!
• Lean Manufacturing | P...
00:00 Intro to the Eight Wastes
00:32 Overproduction Waste
02:04 Transportation Waste
03:03 Excess Inventory Waste
04:42 Rules of Creation of Bonus Stock
08:28 Over-processing Waste
10:55 Wasted Motion
12:50 Waiting Waste
14:30 Misused Brain Power Waste
18:50 People-Centric Lean, Not Profit Centric Lean!
#ShopWaste #PiersonWorkholding #LeanManufacturing - วิทยาศาสตร์และเทคโนโลยี
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The overtime thing hits hard. I work where it is optional and now I’m feeling guilty.
On another note I enjoy all of your videos. Really inspiring and entertaining.
My favorite Lean lesson:
Lean is NOT a destination, it's a journey that never ends.
My second favorite Lean lesson:
Lean is NOT a directive from on high. It it a mindset for each individual that results in a positive culture. Outstanding productivity is simply a byproduct of a great company culture. 👏
Love your parts and information. Thanks!
What i do for parts when removing them from the machine with coolant, I have a suitable bucket of water by the door. I don't even blow it off, just drop it in the bucket, blow off the vise, install the new part and cycle start. Then I remove the part from the water and clean and inspect while the machine is running. Then you can dump the water right into the coolant tank when it gets too much coolant in the water and repeat. This also stops excess coolant mist in the air which is better for the operator.
This is a fantastic series. Looking forward to seeing way more of this!!
Thanks for watching! Please share it with someone if you don't mind. - JP
Awesome video, thanks for sharing.
Loved what Chris said about the Kamban system. I love using it and it makes working very easy and keeps us from running out of products we need.
Great content. I will definitely refer to this video periodically in the future.
Lean starts with Leadership. I see great Leadership going on here.
Awesome content Jay!
This is awesome, thank you very much for what you are doing
Great video John
Thankyou so much for sharing.
Hi Jay. I know your work does not fall into this bracket but it would be so great if you could one day explore the implementation of lean practices and making efficiencies in the high mix, low volume (down to 1-off) manufacturing environment, with a whole lotta skill requirement, a lot of manual input, and of course a lot of inconsistency and chaos. Either that or point me in the direction of those who have managed to successfully do this. Many thanks from the UK
THIS is quality.
Looks like I have a toothbrush design challenge on my hands. 🤩
Sir, I am from India working on Spindle Design Domain. Love your videos as they motivate and inspire me a lot to become a better designer. May I know which Cad software are you using in your Company ?
You should see the waste at my work. Just this week I put 2+ meter ton kg of scrapped parts away ((stainless steels anything from nothing much to inconel and so on so on on top of that with coatings and stuff) theys were good setup material tho) because we set up a robot. And the wasted space from having waste machines that just sit there never get used anymore.
Ouch!
@@Factory400 Nothing to sweat about. Is expensive when yous think about it but the machines I play or rather fight with is junk. Is more or less about 5 years worth or junk there. But the overall state of the shop is ouch for sure :_D
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I appreciate your viewpoints on Brain power.. I am intrigued by your definition of LEAN (Brain Power) is slightly different than what I've learned in Six Sigma. Non-utilized Employee Talent is how I learned it as... and that to me has a broader application.
I.e...
Example #1)
Employee #1 is good @ operating a saw, but you have them driving a fork lift, because that's what they were hired to do. (If if you don't give them an opportunity to fail or succeed @ another position in the shop, you will never recognize their talents)
Example # 2)
Employee #2 is a machine operator, but you have them pushing a broom, because you don't have any material for them to put in the machine.
"Non utilized employee talent" is too narrow and is a poor definition taught in Six Sigma (BTW, Lean Six Sigma is the epitome of profit-centric lean). "Misused Brainpower" expands the definition to emphasize not engaging in low brainpower tasks.
I watch all your videos. If I was in your city I would have asked you for a job. I like the way you work. I work in Chelmsford Massachusetts. And I'm working on a large order for a 20×12 plate and I told the boss we need a vacuum plate. And I buy it.
I hope it works out for you!
This is all good but you make your own products and with that you can have a set system but I've got in a round about way a job shop one day I'll be wire cutting the next milling the next turning so from one to the next it's never the same unless I get production work and now the biggest problem for me is getting materials in [UK] , I had a job to make 300 parts, I had enough 38mm bar to do 40, it took me 3 weeks to get enough metal in and then I had to buy 40mm because no one had 38mm, luckily the customer was understanding but still kept the pressure on. I would love to be able use lean ideas but it wouldn't work due to a vast array of different jobs that I do. I'm in the boat with 99% of other toolmakers looking for that niche market to make own products. 👍
Keep in mind, what someone does has nothing to do with the practice of identifying and eliminating waste through continual improvement. If you can apply Lean in the bathroom, you can apply it anywhere.
@@PiersonWorkholding I understand how not to waste time on pointless back and forth, I had a guy once that used to go to rack get a centre drill go to the machine then go back to get a drill then go get a tap then get tap rench, they only lasted a week before he really pissed me off, for guys like you who have their own product then you know how to plan out, don't get me wrong every wasted minute costs the owner which in turn makes the product more costly. 👍 Thanks for replying.
Where do you get the white tray you use for your lathe parts?
Check out piersonworkholding.com/lean for links to resources
I have heard you mention about debureing or chamfering in the machine as much as possible to minimize over processing and wasted motion. I had a disagreement with my boss regarding things being deburred outside on the machine because so long as you can do so within process of your next piece running you are saving cycle time. I can’t see why you wouldn’t add a couple minutes to a for example 45 minute cycle time vs. spending 30 of it to deburr a large contour while the next part is running, then repeat. What would your argument or standpoint be on that scenario? Thank you it means a ton!
Chamfering and/or deburring outside of the machine ties up the most important asset in the shop - people! This is a misuse of brainpower by doing a relatively dumb task. Humans are very inconsistent when it comes to hand work and are also prone to defects (another lean waste) by deburring too heavy, slipping and damaging the part (or injuring themselves), or missing an edge altogether. Ideally, people should never do the work that a machine can do. If you're twiddling your thumbs because the machine took away your deburring task, GREAT! Use that time to improve your work area or process.
The other way to look at it is "lean " is also the reason people can't get parts ... example I can't even get a spindle belt for a cnc mill because gates is 2 months out on making them ... and none of the "distributors " even stock them ..all they do is drop ship
A lot of that is outsourcing. When the shipping delays hit, it showed how much transportation waste there actually is.
I just don't think lean has got anything to do with that.
@@krenthabohl seems like it wouldn't be a problem if Gates actually had extras on hand... it's just one example , lots of people waiting on parts that have no ETA...
Lean is about eliminating waste. When the supply chain is in good condition, companies can avoid waste by excess inventory.
When the supply chain is compromised, a lean company focus on not wasting opportunities. That is done by altering what you define as excess inventory.
On this particular day....to be lean you need to think further ahead to avoid waste. Many companies are struggling to make that expensive change in operations.
Probably a little over half of this video is stuff I never would've thought of on my own.
How can we continue operating in a lean/JIT fashion when the supply chain issues in the last few years have taught us that we probably need to stock more raw materials because you might not be able to get it when need them.
It's an anomaly. If every step of the supply chain is struggling to get supplies, nothing, including Lean, can help in the short term.
Ergonomics is crucial, so is mental Ergonomics, it seems you have included this without saying it.
Uuuuuuuuuu yesssss lets goooooooooooo
I do not see how running a full year’s worth of parts at a time is lean, regardless of the size or cost. In my mind a lean process would be to get the kanban to a reasonable level and work on optimizing machine setup times. If it takes an inordinate amount of time to set up a part then look at part design, tooling or setup procedures to get closer to the “Single Minute Exchange of Die (SMED) concept.
Good observation. Allow me to explain. First of all, this is specific to a bar fed lathe running small parts since it runs unattended. By running 1 component for 1 month, we only transport material 1 time per year (transportation). We only need 1 spot for the raw material, not a large material track for multiple bar sizes (excess inventory). All setups, even smed setups, are overprocessing so 1 setup per year vs 4 quarterly setups reduces overprocessing. Ultimately, who gets to decide what is too long? Is 1 week, 1 month, 1 year, 1 decade too much inventory? In our case, making a year's worth of components on this specific machine works perfectly.
@@PiersonWorkholding If that machine does nothing but those specific parts and has no free time that could be utilized then reducing setups is obviously desirable. I would still be nervous about “buying” that much finished inventory at one time.
I f your guys are so good why would you insult them by calling them "rock stars"?
Would you prefer ballet stars? 🩰
@@PiersonWorkholding might be as egotistical,but maybe less demonic! Only serious.l know whereof I speak.
Lean is a good tool but it's not perfect it's only work when people come together and make a system to works and something works in one shop but it not sure it always work in our shop so it has to be tailor made To every shop.
experience from 22 years of working with lean
Yes, Lean, like any tool, only works if people use it.
Get a bigger building buy everything in bulk. That's how you make money
100% total opposite, completely wrong, fail. Would delete but I gotta make an example out of you.
Your company seems like a great place to work. Except for being located in the communist hellscape of Cali. Doesn’t that go against your lean practice of waste? That’s the most expensive state to run a business in and I’d imagine you could save a boatload of money by evacuating immediately.
Which of the 8 wastes does being located in California violate?
I was curious about the lean manufacturing principles that you talk about. I was serious when I said I think your company would be a great place to work. Are you saying that you couldn’t pass savings on to the customer if you were in a more business friendly state. I imagine the money saved if you were in a state like FL for instance would be an order of magnitude over say #6 (wasted motion).
@@PiersonWorkholding Cali has human waste on the streets of their cites.