Great example of small practical Lean improvements at the Gemba. We love the enthusiasm of both the coach / manager and the worker. At ILSSI our goal is to educate and motivate all companies to have this culture, behavior and way of thinking.
A 50% time savings is remarkable! I gotta ask though: how does the label get applied to the first side of the roll and why doesn't the roll get flipped at that point and the second label get applied the same way? Seems that would be a nearly 100% time savings. There must be a good reason but it's not obvious...
There’s a very good reason that’s not obvious at all! - The machine that shrink wraps them has the ability to apply a label, but can only apply a label to 1 side of the package. The investment in a new machine is in consideration, but they are not cheap at all - and there's lots of other machines we want too! Lukas
Got it. I'm really impressed by how engaged you guys are with your work. Sometimes a bit of clever thinking is the best substitute for expensive machines! After all, it's not what you've got but how you use it that matters most :-)
Why not locate the two label dispenser/alignment jigs side-by-side to eliminate the excess motion of double-handling the rolls? This will allow a better one-piece flow. So the operator would grab tape from box, put on front & back labels, then put in shipping box. Completely eliminates the middle step. Hope this helps! Great job Fastcap!
Paul, another suggestion would be to rotate the "Final Package" on it's side just like the other package in the last Lean improvement... so that way after attaching the end label there is no rotating of the wrist, and that having it all be in one side... plus having gravity help tamp down the end label. Good Work team!
jjlwis I'll pass this on to Lukas. Frankly, I'm sure he has already made changes since the video. That's the beauty of continuous improvement and staff excited about fixing what bugs them! Paul
I feel like placing the input and output of the process closer to each other would be an improvement. When I complete a process, the same hand that delivers my output should be retrieving the next input.
I wonder if he could shave a few more seconds by just making a short stack to the right side of the label dispenser and after say 5+ rolls do one large stack into the box instead of individually. My thinking is that after he labels a roll there is a look to the box and a long reach to set the roll in each time while the left hand is idle. If he made a short stack to the right he could continue looking down for a longer period of time and while the right hand is stacking the finished roll to the right side the left could be grabbing a new one and placing in on the light. On the right hands return to the new roll he could grab a label, apply it and repeat without having to turn his head or twist his body every roll.
Hi Paul and Lukas, you are probably significantly improve this process with regard to the date of publication of video. Regardless, I think that this process can be improved. I think that fixed reference foam on the table can be removed. Move tape machine on the edge of the table, and just take the tape and just moving the tape from the bottom to the top you can pick up a labels sticking it directly on the tape. Less motion. You don't have to put the tape on the reference-and pick a label then stick that's all gone. Lean is simple! :D
Thanks so much for the suggestion! I just tried this method and found it wasn't feasible. You cannot get the label on in a quality way, and its not actually much faster because it requires adding a flip to the Speed Tape to see which way the front label is facing. More importantly though trying to apply the label without pulling it off by hand doesn’t work at all, and creates a huge mess as well as defective product. But it help prove our thought that the best answers can be found on the shop floor through experimentation and we will continually work on this! Lukas
@@FastCapLLC I was thinking maybe making the reference foam taller to accommodate a stack of product for labeling. Then move a finished stack into the box instead of one at a time.
If you could fit everything on it, maybe you could get away with only a front label that's printed on both sides. The back side would be printed in the middle and would be read _through_ the hole in the tape.
I’m studying lean-6 sigma and bumped into this video by accident. First off good job on the improvements but doing a “virtual” gem a of what the employee is doing I was wondering ‘Why don’t you place the outbox vertical too?” The rolls would never have to rotate(flip). More motion time waste removed.
I'm a bit confused..is Lucas trying to orient the labels to each other on opposite sides? If that is the case I would ask...why? Or is this operation designed to center the labels on the roll? If it is to center the labels here is a suggestion. Put the positioning mold right under where the labels scroll out, centered of course. That gives you the left to right position from the get go. For the top to bottom position a laser light from above would show the operator where to drop the label. Easy Peasy. Centering is of course important to show attention to detail. However, the customer loves the product...the label centering can certainly be off perfect center a little and that would not be a concern to the customer. What happens when the customer starts using the product....it's like Christmas morning...let the ripping and tear off begin.
Our goal is quality above all else. So while it may not matter, if we are going to apply a sticker, we want to apply it with quality. Therefore we are not only centering it, but aligning the rotation to match that of the front label. Our product sit on distributors shelves for sale, and we want the packaging to look as quality as we know the product is, so that new customers trust the quality and try our products out, so that they fall in love! Lukas
Why it is not one piece flow, I mean, why he is not sticking front and back labels at the same time. It seems like he is doing fronts first then backs, which is kinda batching for me.
Hello I like your "lean" concept. I can see it being a great method to bring efficiency. I humbly suggest that the entire "align the label" process is an inefficiency. The vendor must take the face side of the label and place the product on the shelf. They should orientated that for the customer. IF the customer wants to read the back, why is an issue for them to orientate it so they can read it? 99.9% sure this does not affect sales. The bar code scanner works in any orientation, so alignment is moot for this issue. Is this whole focus a waste of energy and resources? What are your thoughts to this challenge? again, not being a troll, just asking you to explain and defend- maybe both of can grow from the discussion. Thank you
me It's called standardization. It is incredibly important to have clearly defined processes or they denigrate by nature. For the same reason, when you pick up a cereal box the labels are all north up. certainly it doesn't matter because you could re-orientate the box for your eyes but this consistency transfers to the entire process of everything you do in terms of the pursuit. Quality and consistency for the customers experience. Paul
Great Example! By the Way, I was on the phone with a sales guy at Woodmizer yesterday and found out he knew what 2 second lean was and had watched Fastcap videos. Unfortunately I asked some more in depth questions that he should have been able to answer but couldn't and it doesn't didn't sound like they've truly embraced it.
@@FastCapLLC I tried applying lean to two previous jobs with no success. When you aren't the boss it is hard to make change even when it is more efficient. Some people like keeping things the same way it has always been done which drives me nuts. If that was the case why use tractors, cars, cell phones etc?
Looks like he's flipping the label each time he applys it from barcode up to barcode down.... also seems like the labels are not oriented the same way on each roll. You could save the flip by changing the 2nd label orientation to match the other station.
Congratulations on an efficiency that apparently you needed. Now ask yourself, better yet go view consumers looking at labels, and see what (if any) reading of one let alone two labels takes place. Personally I purchase tape based on the need, desired result, and the quality of the manufacturer. Thus the display and organization of the retail outlet is more use than product labels. (3 letters preceding N, a water fowl, are brands that I look for to handle 100% of the jobs.) I love your products, but I think you are over thinking the labels, IMHO.
@@FastCapLLC One option is getting the sticky side of the first label printed with that information instead. Then it is applied automatically in the wrapping. I have seen food products like this.
man, you and your team members really showed case the beauty of the spirit of TPS
Thanks so much, Jackson!
I want a job like this. Process improvement seems like a fun job that makes a lot of sense to me. There is always a better way
+Hunter Anderson I totally agree. 2 Second Lean is A LOT of fun! And it is so much better to make work fun, and improve and you go!
I would love to work around people who are always optimizing processes.
Great example of small practical Lean improvements at the Gemba. We love the enthusiasm of both the coach / manager and the worker. At ILSSI our goal is to educate and motivate all companies to have this culture, behavior and way of thinking.
I will show this video in tomorrows morning meeting . Thank you Paul and Lucas
Plastic Promotions Ltd Cool!
Really nice! I've been sharing Lean all week with close buddies and family. Keep going guys. You've got a convert right here!
Okinawa Japan Great! Why don't you send me some before/after videos! Paul@fastcap.com
Nice job!
A 50% time savings is remarkable!
I gotta ask though: how does the label get applied to the first side of the roll and why doesn't the roll get flipped at that point and the second label get applied the same way? Seems that would be a nearly 100% time savings. There must be a good reason but it's not obvious...
There’s a very good reason that’s not obvious at all! - The machine that shrink wraps them has the ability to apply a label, but can only apply a label to 1 side of the package. The investment in a new machine is in consideration, but they are not cheap at all - and there's lots of other machines we want too! Lukas
Got it. I'm really impressed by how engaged you guys are with your work. Sometimes a bit of clever thinking is the best substitute for expensive machines! After all, it's not what you've got but how you use it that matters most :-)
We call it "using our wits, not our wallets!"
Hope that means you get profit sharing and/or stock options :-)
Why not locate the two label dispenser/alignment jigs side-by-side to eliminate the excess motion of double-handling the rolls? This will allow a better one-piece flow. So the operator would grab tape from box, put on front & back labels, then put in shipping box. Completely eliminates the middle step. Hope this helps! Great job Fastcap!
good idea.
Great job guys
Paul, another suggestion would be to rotate the "Final Package" on it's side just like the other package in the last Lean improvement... so that way after attaching the end label there is no rotating of the wrist, and that having it all be in one side... plus having gravity help tamp down the end label. Good Work team!
jjlwis I'll pass this on to Lukas. Frankly, I'm sure he has already made changes since the video. That's the beauty of continuous improvement and staff excited about fixing what bugs them! Paul
what about stacking vertical in the last box too?
Good idea!
At 2:03 - habits, how many literations tikl disapear? :)
Great example of CI, thanks
+Andy Richards You welcome.
pretty sure the one done at 3:39 was centered - no inspection -defect passed to customer. this process should be automated
I feel like placing the input and output of the process closer to each other would be an improvement. When I complete a process, the same hand that delivers my output should be retrieving the next input.
There is always room for improvement!
I wonder if he could shave a few more seconds by just making a short stack to the right side of the label dispenser and after say 5+ rolls do one large stack into the box instead of individually. My thinking is that after he labels a roll there is a look to the box and a long reach to set the roll in each time while the left hand is idle. If he made a short stack to the right he could continue looking down for a longer period of time and while the right hand is stacking the finished roll to the right side the left could be grabbing a new one and placing in on the light. On the right hands return to the new roll he could grab a label, apply it and repeat without having to turn his head or twist his body every roll.
***** I'll pass this along, but keep in mind we process improve every day, so I'm sure this process has already change a lot!
Hi Paul and Lukas, you are probably significantly improve this process with regard to the date of publication of video. Regardless, I think that this process can be improved. I think that fixed reference foam on the table can be removed. Move tape machine on the edge of the table, and just take the tape and just moving the tape from the bottom to the top you can pick up a labels sticking it directly on the tape. Less motion. You don't have to put the tape on the reference-and pick a label then stick that's all gone. Lean is simple! :D
Thanks so much for the suggestion! I just tried this method and found it wasn't feasible. You cannot get the label on in a quality way, and its not actually much faster because it requires adding a flip to the Speed Tape to see which way the front label is facing. More importantly though trying to apply the label without pulling it off by hand doesn’t work at all, and creates a huge mess as well as defective product. But it help prove our thought that the best answers can be found on the shop floor through experimentation and we will continually work on this! Lukas
@@FastCapLLC I was thinking maybe making the reference foam taller to accommodate a stack of product for labeling. Then move a finished stack into the box instead of one at a time.
What is the name that machine on the label? thanks
The label machine is retailed by U-Line, product H-1981, 115V 1.7A 60 Hz www.uline.com
very cool!
If you could fit everything on it, maybe you could get away with only a front label that's printed on both sides. The back side would be printed in the middle and would be read _through_ the hole in the tape.
J DeWitt There is important info on the back label. It's important that it's visible and easy to read. Paul
I’m studying lean-6 sigma and bumped into this video by accident. First off good job on the improvements but doing a “virtual” gem a of what the employee is doing I was wondering ‘Why don’t you place the outbox vertical too?” The rolls would never have to rotate(flip). More motion time waste removed.
Thanks for the feedback. I'll pass it on.
I'm a bit confused..is Lucas trying to orient the labels to each other on opposite sides? If that is the case I would ask...why? Or is this operation designed to center the labels on the roll? If it is to center the labels here is a suggestion. Put the positioning mold right under where the labels scroll out, centered of course. That gives you the left to right position from the get go. For the top to bottom position a laser light from above would show the operator where to drop the label. Easy Peasy. Centering is of course important to show attention to detail. However, the customer loves the product...the label centering can certainly be off perfect center a little and that would not be a concern to the customer. What happens when the customer starts using the product....it's like Christmas morning...let the ripping and tear off begin.
Our goal is quality above all else. So while it may not matter, if we are going to apply a sticker, we want to apply it with quality. Therefore we are not only centering it, but aligning the rotation to match that of the front label. Our product sit on distributors shelves for sale, and we want the packaging to look as quality as we know the product is, so that new customers trust the quality and try our products out, so that they fall in love! Lukas
Why it is not one piece flow, I mean, why he is not sticking front and back labels at the same time. It seems like he is doing fronts first then backs, which is kinda batching for me.
They are packaged using a machine. The machine only has the ability to do one label per roll so the other is done by hand.
The tape can't be ran back thru the same machine to just label the other side? Is that possible to do? Does it take longer to do it that way?
Hello I like your "lean" concept. I can see it being a great method to bring efficiency.
I humbly suggest that the entire "align the label" process is an inefficiency.
The vendor must take the face side of the label and place the product on the shelf. They should orientated that for the customer.
IF the customer wants to read the back, why is an issue for them to orientate it so they can read it? 99.9% sure this does not affect sales.
The bar code scanner works in any orientation, so alignment is moot for this issue.
Is this whole focus a waste of energy and resources?
What are your thoughts to this challenge?
again, not being a troll, just asking you to explain and defend- maybe both of can grow from the discussion.
Thank you
me It's called standardization. It is incredibly important to have clearly defined processes or they denigrate by nature. For the same reason, when you pick up a cereal box the labels are all north up. certainly it doesn't matter because you could re-orientate the box for your eyes but this consistency transfers to the entire process of everything you do in terms of the pursuit. Quality and consistency for the customers experience. Paul
FastCap ok-good answer.
thanks for responding
Great Example! By the Way, I was on the phone with a sales guy at Woodmizer yesterday and found out he knew what 2 second lean was and had watched Fastcap videos. Unfortunately I asked some more in depth questions that he should have been able to answer but couldn't and it doesn't didn't sound like they've truly embraced it.
falfas55bgas Brad, Sometimes it takes people longer than others. Paul
@@FastCapLLC I tried applying lean to two previous jobs with no success. When you aren't the boss it is hard to make change even when it is more efficient. Some people like keeping things the same way it has always been done which drives me nuts. If that was the case why use tractors, cars, cell phones etc?
Well done. 40 minutes from 120 is cutting by 2 thirds (-67%). Don't sell yourself short by stating 50%.
Looks like he's flipping the label each time he applys it from barcode up to barcode down.... also seems like the labels are not oriented the same way on each roll. You could save the flip by changing the 2nd label orientation to match the other station.
That's what makes Lean so good...always improving!
👍👍👍👍
If possible, eliminate the second label altogether
He said it is a technical product that requires information on that second label.
If you eliminate the box and the product, boom. You save all the time.
ha!
Congratulations on an efficiency that apparently you needed.
Now ask yourself, better yet go view consumers looking at labels, and see what (if any) reading of one let alone two labels takes place. Personally I purchase tape based on the need, desired result, and the quality of the manufacturer. Thus the display and organization of the retail outlet is more use than product labels. (3 letters preceding N, a water fowl, are brands that I look for to handle 100% of the jobs.)
I love your products, but I think you are over thinking the labels, IMHO.
SuperYtviewer Great point, but it is a technical product and it is important infornation in order to use it successfully. Paul
@@FastCapLLC One option is getting the sticky side of the first label printed with that information instead. Then it is applied automatically in the wrapping. I have seen food products like this.
;
Is this a joke