Wow, I wish every workplace was this neat and efficient! Sometimes when I'm in workspaces, I can literally feel the stress come on when I see how messy, dingy and poorly lit things are. It's super inefficient and stressful. But I loved FastCap's simplification measures, e.g., the label-making/printing instructions, the vacuum that's built into the pipe cutting area, etc. If every company implemented these sorts of methods, we could switch to a 32-hour workweek instead of a 40-hour workweek. In my humble opinion.
Respect! It's one thing to think up ideas for a lean and tidy workplace, but actually DOING it and KEEPING it that way in the entire company takes a ton of commitment and team spirit. Much to learn from this video.
The idea of having an open floor concept can be very beneficial especially when it is a team working together rather than several small teams with a lack of communication and their own agendas. Everything labeled and organized goes a long way to ensuring you and your team have everything you need to succeed.
This is a wonderful example of lean manufacturing that is interesting, has excellent video and audio quality, and most importantly to me, is accessible to my high school engineering students. I so appreciate your making this video tour. Wishing you all the best and continued success at FastCap!
I just had to watch this for one of my manufacturing classes. I can only hope I'm lucky enough to one day work for a company with such a friendly, yet professional atmosphere like this
This video used to be an introductory part of Lean training at an auto parts manufacturer. Now I suggest this video to clients as a consultant. Excellent demonstration of the tools and ownership by employees.
Great video, really changed my view of the work environment and help me in a presentation at my work where I showed this video. Talking about lean this is a great visual tool for outsiders and newbys to see what's lean really supposed to be like and look like. Cheers !!
I don't even know how I stumbled across this video, but after watching it I really have a serious appreciation for your business, business model and this 'lean' concept. I've purchased some Kaizen foam (which I love) from you in the past but I"m going to take a closer look at your website to see what else you may sell that could improve my shop expierence. I really want to support businesses your yours and hope others do as well. We need more US manufacturing like this. Pride in product and positive work culture. Great work guys.
Paul, I had the honor of meeting you when I worked for a cabinet hardware supply store in Houston. We met at a trade show and I have always remembered that moment. At my current job we have just started using the Kanban system and I refer to your videos all the time to show people how it can work perfectly.
I hope to open a very small food production factory. This video is AMAZING & such an inspiration. So well organized. This will stay in my mind as the ideal. Love all that natural sunlight too. ☺️
Just WOW. Leanest and meanest factory I have ever seen. I'm a production manager trying to start the lean journey and let me tell you that was absolutely the leanest facility I have ever seen. Great job Fastcap.
Paul, awesome video and great memory. Seems like we are there all over again. Every inch of FastCap is magical, thanks. You are my true north. take care, John
John, the notion that we can collaborate and work together to improve the world is very gratifying. I view us as a team all working to the same goal! Paul
Good job there, although, I'm not sure about the switches, I think there is a thin line that divides where to look for efficiency and it is when you lose focus on the element's functions and prefer to use another reference like the red lines in the case of aircraft switches; I mean that the tendency becomes preferring avoiding time waste and reasoning after instead of reasoning quickly, so you understand what you are doing first.
I very recently got promoted to an Engineer (I started in the factory as a temp production line worker, just loading PCBs into a conformal coat machine). The key point I saw here is having your Engineers in the production area!. This is a fantastic idea!.. as a production line worker it was easy for me to notice ways to improve processes, but the engineers were in the complete opposite end of the building, making it REALLY hard to get those inefficiencies rectified. I've been fighting (and slowly winning) in really trying to improve communication between engineering and production sides of the business. But Physical proximity seems to be a great idea. If you don't hide the Engineers away in an office at the end of the building it can help the flow of feedback.. really get the Kaizen process to flow much faster.. I'm still a very junior engineer (so much to learn every day) but I just LOVE to learn. and more than I love to learn I love to improve processes that are totally arse backwards and fix them... I hate to hear "But that's how we've always done it" and am really trying to change the culture to abandon that kind of thinking. EDIT FROM HERE: Your plane system.. fantastic. An aviation buff myself I love this idea of unambiguous switch positioning, Very 'Airbus' Philophosy. The airbus philophosy being ALL switches should be in an identical visual state when in the 'correct' position.
wow, just amazing lean manufacturing. Great creativity for all the 6s tool holdings. Been working on the place I work at to even start with any of this, but I still cant even get a Bidet for years like yours.
I noticed your floors are concrete. Over time standing and walking on such a hard surface wears on the body. Back and knees are affected and can do long lasting damage.
Especially a company like this when they have a standing only policy and you can't sit down to take a quick break while working at your computer to gather yourself. I'm sure they have chairs in their break room but having no chairs at their actual work area, that's kind of ridiculous. I personally prefer to stand while working at my computer but atleast my company gives you the option. We have computer desks that you can lift so you can stand while working on your computer or recline it so you can sit at your computer because standing in one spot all day will wear your back and heels out.
Hi Paul, you took us on a quick tour some months ago of your new facility whilst I was doing some business with Bob Lodder. Really appreciated your time then and really appreciate this video that I'll share with my managers. It really is amazing what you have done and many thanks for sharing once again.
Great information share! Enjoyed seeing examples! At 4:12 there is a lot of inventory being shown on shelves. Not sure the process - just caught my eye. Thanks!
Enthusiasm City ! ! ! I love your creativity, Paul, well matched to your energy and laser-focus. Plus, bidets in the restrooms! What more could an employee ask for?
Easy of access, and three Big Ass Fans! While I don't understanding the standing, I can appreciated the 'U' format that allows the processes to flow with extreme ease. Yes-Haw!!!!
I’ve been standing full time for 2 years, often 12 hours a day. Of course I sit at breaks. But I own the company and was the first to do it before my team. We have anti fatigue mats. I would never go back to sitting. Not a chance.
Really impressed. I'm sure the many efficiencies have many benefits including quality service, staff motivation and maximum sales. Well done to Paul and all the team. This is a great example of the importance of Leadership nurturing a Lean culture and staff buying into the philosophy.
Paul! I loved this video! Being a maker/inventor/fabricator... You look like a fun cat to hang out with... Having things organized in your warehouse and having it all super clean is a lot of work but it truly makes for a more enjoyable ride on the scooter when you don't slip on dust bunnies... Loved the scooter mods they did to their scooters...... For sure looks like a fun place to work.... -Brian
The color coding by days of the week to see and measure flow and if you are on time is a good idea. The simple things like that and the toolboxes to have the shadow cutouts make it easier for work flow and the ability to be agile and others to substitute in and know where things are.
What an amazing operation. The new location is very sweet. I've served packaging equipment at both the old and new location and I'm extremely impressed. The employees are extremely friendly and a pleasure to work with and you can tell they love what they do. Coming from a hobbyist woodworker I love what there doing and am not ashamed to admit to drooling a little when I visit.
It's crazy how they took away sitting. This is a high functioning plant without any non-value adding steps. It's so efficient, a person on their first day can print out so many levels.
I think the most important thing that this company does is 3S for a dedicated 15 minutes every day. It's not a ton of time taken from the overall day, but it is enough time to insure that everything is clean and organized, every day.
@Have a nice time! Yes we do apply the Kanban method. Check out this video:th-cam.com/video/Levkx8f0qL4/w-d-xo.html It shows all our Kanbans that we use throughout the facility.
Congratulations you all have done a great work, I am a quality engineer and I appreciate when everyone works as a team to keep everything organized, clean and a good work flow, this as you mentioned it keeps everything smooth, enjoy to work, less waste of time. If you ever need a QA let me know lol!
If you all ever open a facility in Reno, I'll be the first to apply!!! It looks so much like home that I'd relocate in a heartbeat if you were only in a sunny place!!! 😍😍😍Seriously, my fantasy workplace!!!!
Awesome! I wish I will work in a place like this some day! I dont have words, it must be really motivating towork like this! I havent seen a company like this before... Greetings from Germany ;)
+Telias Thanks so much. Check out my website for a bunch of lean information. paulakers.net/ Also, I though you might like this video. th-cam.com/video/DhRjlIkj2Nw/w-d-xo.html
This video is a great way to show how lean can be applied to any industry and way facility in their own way. I loved how the concepts of lean and six sigma were applied to different areas of the facility and processes.
Thank you so much for uploading this video. I am currently implementing Lean at my new office and we are loving it. However, I wanted to view others to see what fantastic ideas they have come up with that we hadn't. Thanks again, this is great.
You're welcome. You should subscribe to by weekly 2 Second Lean email. I pick a video each week to share...either from me, FastCap or one that was sent to me (make sure you scroll down and select 2 Second Lean) bit.ly/FastCap-Subscribe
On the topic of scooters: This may be a silly question...would employee's need to sign a waiver before using a scooter? This way if employee's fall and bump their necks, as an example of injury, you won't be help liable for workers compensation due to on-site injury? Overall, the scooter in my opinion is perfect to use in your large facility. Thanks.
One thing I've noticed about Lean is that it has to be a company culture. You can't think, "that's a problem for someone else." You also can't have a situation where you feel like your work is wasted because the next guy in line is going to mess everything up. For instance, if 1st shift sees a shelf that needs to be organized, does so and then the next morning they see that second shift made a mess of the shelf, they feel a sense of defeat. Why would I make improvements if they're just going to be undone? The other problem is managerial misunderstanding of the concept. Many companies think that never buying needed tools, spending money on maintenance or taking time now to improve efficiency for later saves them money, so that must be what Lean is all about. What they don't realize is that money saved in the short term is often money lost in the long term. They'll offshore their production resulting in long lead times and inventory excess when it finally arrives, pay bottom dollar leading to employees who are under qualified and high turnover rates, use the phrase "that's how we've always done it" (I hate this phrase. Never say this.) leading to stagnation, neglect the brain power of their workers leading to dissatisfaction, fail to upgrade and improve, and when they do finally have no choice but to replace something, they seek the cheapest rather than the best for the process leading to lost opportunity due to down time and inefficiency. When I first hired onto my current company, they talked about improving efficiency and wanting to implement Lean concepts. Now that I've worked there a few months, I can see that they don't understand what needs to be done. I have made several suggestions for improvements and all have been dismissed. I have made several requests for more efficient tooling and all have been ignored. So I've decided that I need to step up or move on. I'm working on several proposals for equipment, technology and processes that will greatly improve efficiency/productivity. This post is getting long, but I developed a little example to show how small savings end up big over time: 9 seconds = 65 hours. If you make 100 widgets per 8 hour day that means it takes 4 minutes 48 seconds per widget. If you find some way to improve that by a mere 9 seconds per widget, you gain 65 hours of extra production per year. 9 sec times 100 widgets times 5 days times 52 weeks = 234,000 seconds divided by 60 = 3,900 minutes divided by 60 = 65 hours. 1 week, 3 days and 1 hour of production you didn't have before. That's an extra 812.5 widgets per year and if you make $10 profit per widget...$8125 from nothing more than making a 3% improvement to the process.
Kenneth, I just started a new job as a Manufacturing Engineer/Process Optimizer with very similar issues to what you've described. I'd love to hear how things went for you, if you have the time. Your comment mirrors a number of my thoughts on the difficulties in applying changes to non-machines. : )
"A minute you struggle, you have waist". Awsome! Paul, seriously ! Thanks for showing me the ins and outs of the Fastcap facility. This give me more respect for Fastcap. I wish the company I worked for would adopt the Lean process. My wife is a Green belt and I tried to adapt some of the Lean process at my work place….and came across some less then willing bosses. Continue to grow…50,000 square feet…..ALMOST the size of my hobby woodworking shop……LOL Just kidding…that place is HUGE! Eric
Thanks Eric. I send out a weekly eBlast on lean. Usually videos I create or others have shared with me. Some of them are folks who struggle with bosses who don't understand. Here is a link to subscribe (select 2 Second Lean). fastcap.us1.list-manage.com/subscribe?u=4b6cd3052005adbfe263c045e&id=8c1f8244f9 Keep me posted on your lean journey!!! Start small! Paul
I still feel that way after years of Lean. Small steps every day. Just pick one improvement and go from there! Share before/after videos, too. It will encourage you to keep going!
Cool video... if I were to guess he constructed that warehouse with Lean on his mind. To get a warehouse to that state after it has been built would be rather difficult and costly. But designing a warehouse with Lean in mind would/could make all the difference.
I love everything you have going on! I have tossing the idea of moving up there and applying for a job. Now that I see you have a jet I could put my A&P skills to work! If only I didn't have time remaining in the AF
very nice video, its great for learning, i have few question , 1. How to sustain the floor? 2. how change mindset of people and make them understand to achieved this lean faster? 4. can you guide me on soap factory how to do lean?
@msnit1988 Here is a message from Paul! Thank you for all the questions, All this information will be able to help you get started on your Lean journey. Our new app called “2 Second Lean Play” has all my books and resources in audio just like The audible app. But everything is FREE.. It even has the classic books that we have recorded "Today and Tomorrow" by Henry Ford (you would swear you were listening to Henry Ford) and “The Toyota Production Handbook” by Taiichi Ohno. We have noticed that not everyone is predisposed to personal development so we wanted to create a platform that has no barriers and zero cost so everyone can easily start their personal development journey to improve their life and their work. We are also getting other authors to make their books available. This project was the vision of Tom Hughes from Ireland. Tom took the ball and ran with it and develop the app and his team did a spectacular job a million thanks Tom. Here is a quick overview videoth-cam.com/video/QxB-oAsNpFI/w-d-xo.html Here is the link on the App Store apps.apple.com/gb/app/2-second-lean-play/id1503694993 For the ANDROID. Here is the link play.google.com/store/apps/details?id=com.leanplay my first app is great for tracking all your daily habits here are the details Lean PD at iTunes Lean PD at Google Play Paul has created the Lean PD App as his simplfied version of the Harada Method. For more information on this App, go to iTunes (bit.ly/LeanPD-iPhone) or Google Play (bit.ly/20WhCeP). Paul has created the Lean PD App as his simplfied version of the Harada Method. For more information on this App, go to iTunes or Google Play. Thanks Paul
Hi Paul, Great tour! I love the way the your facility is set up and how variable processes flow through it. I think every day how we can achieve that in our company. Keep up the good job and thank you so much for sharing the great innovative ideas of your team. Steve K. Spokane Wa.
Absolutely Amazing , To think how many years it's been that I've been doing biz with Your company. And Look how big You guys have grown. Best part is That Lean Mfg . without it You guys would need 10 times the space. Fantastic Paul, Lean Manufacturing at Work! a picture is Truly worth a Million words. Thanks Joe
Great presentation, teamwork, time saving caps.... but i feel like there's still a room for improvement (work flow, inventory and so on). For example small spaces between the aisle what is consuming space, where is JIT?
100% agree. While standing may improve some worker(s) attentiveness and promote other health benefits, it is not always the optimal solution for all employees. I have had a few spinal procedures that would prohibit myself from standing 100% of the time. There are flexible desk options these days. Think HumanScale or FlexDesk. Very informative video. Great lean concepts. The Big Ass fan is highly effective and works everywhere I have seen them.
@@toddcutsuries54 for some reason customers feel like a cashier sitting on a stoll makes them lazy or something and alot if those same people would never allow themselves to be subjected to that
Having done actual work at a facility similar to this design complete with a no-sitting policy, it is GREAT! Sure, it is rough for a while until your body gets used to it, but it is so much better for you than destroying your back with terrible sitting posture (I'm certain that only people with excellent posture will reply. Hear the sarcasm?). However, for people with a medical condition they DO make exceptions. There is always an absolute difference between a WANT and a NEED. Having also done grocery-store work, I can share this: In a place like Walmart it is a VERY different scenario. If you are a cashier then you are STABLE and standing (ie: unnatural standing) which can get you very sore easily. And if you are stocking then you are constantly bending and lifting items and most people have terrible lifting posture which will also ruin their body. Finally: This is how work has been done throughout history. Being able to lounge in your chair at a computer desk is a modern convenience that lets you destroy your back with terrible posture daily. I personally HATE how much pain it causes.
this area has everything my employees have ever asked for, from scooters, to auto pallet wraps, to free food. But it makes me wonder what was the cost to get them there?
I'm a new subscriber and am enjoying your videos. You have a great workplace. The morning meetings are great for keeping everyone focused on the company's mission statement. Also, I believe allowing a different person to be the leader is great for self confidence, and if you're not used to speaking in public, it's a great opportunity in front of your peers, who don't want to see you fail, but to improve. When everyone knows how the company functions, how decisions are made, you as an owner, can feel assured that when you're on a trip, you won't come home to a disaster. Also, you could pick anyone from your group to give a tour and they'd be able to show and explain to visitors how everything works, and answer just about any question. Thanks for sharing.
Wow, I wish every workplace was this neat and efficient! Sometimes when I'm in workspaces, I can literally feel the stress come on when I see how messy, dingy and poorly lit things are. It's super inefficient and stressful. But I loved FastCap's simplification measures, e.g., the label-making/printing instructions, the vacuum that's built into the pipe cutting area, etc. If every company implemented these sorts of methods, we could switch to a 32-hour workweek instead of a 40-hour workweek. In my humble opinion.
Respect! It's one thing to think up ideas for a lean and tidy workplace, but actually DOING it and KEEPING it that way in the entire company takes a ton of commitment and team spirit. Much to learn from this video.
Just watching this video has given me ideas on how I can make working fun and easy at the company I currently work. I love the shrink wrapper idea!
The idea of having an open floor concept can be very beneficial especially when it is a team working together rather than several small teams with a lack of communication and their own agendas. Everything labeled and organized goes a long way to ensuring you and your team have everything you need to succeed.
Thanks For showing great example of Lean including Visuals .
Great.
This is a wonderful example of lean manufacturing that is interesting, has excellent video and audio quality, and most importantly to me, is accessible to my high school engineering students. I so appreciate your making this video tour. Wishing you all the best and continued success at FastCap!
I just had to watch this for one of my manufacturing classes. I can only hope I'm lucky enough to one day work for a company with such a friendly, yet professional atmosphere like this
same here haha lol
This video used to be an introductory part of Lean training at an auto parts manufacturer. Now I suggest this video to clients as a consultant. Excellent demonstration of the tools and ownership by employees.
Thanks, Greg! Have you seen FastCap Tour 2.0? th-cam.com/video/EqtKKkastWk/w-d-xo.html
Love everything on wheels, no chairs, color coding, visual ques
Great video, really changed my view of the work environment and help me in a presentation at my work where I showed this video. Talking about lean this is a great visual tool for outsiders and newbys to see what's lean really supposed to be like and look like. Cheers !!
I don't even know how I stumbled across this video, but after watching it I really have a serious appreciation for your business, business model and this 'lean' concept. I've purchased some Kaizen foam (which I love) from you in the past but I"m going to take a closer look at your website to see what else you may sell that could improve my shop expierence. I really want to support businesses your yours and hope others do as well. We need more US manufacturing like this. Pride in product and positive work culture. Great work guys.
Thanks so much. That means a lot to me. And if you want to learn more about Lean, stumble over to my website paulakers.net/
Nice! Shop workers stand all day, so it’s good to see equality throughout
Try to stand 8 hours 5 days a week and you will hate this job. People have to seat at work unless it’s dangerous
Paul, I had the honor of meeting you when I worked for a cabinet hardware supply store in Houston. We met at a trade show and I have always remembered that moment. At my current job we have just started using the Kanban system and I refer to your videos all the time to show people how it can work perfectly.
Thanks so much for sharing this! You guys should start making before/after videos and sharing them, too!
So efficient and organized. Everyone seems friendly and happy. Looks like a great place to work!
What an amazing facility; Lean concepts from top to bottom and across all departments. "See waste, think lean!'
I hope to open a very small food production factory. This video is AMAZING & such an inspiration. So well organized. This will stay in my mind as the ideal. Love all that natural sunlight too. ☺️
WOW! Very impressive. Awesome environment.
I love your videos, they are a source of inspiration for my future occupation
Just WOW. Leanest and meanest factory I have ever seen. I'm a production manager trying to start the lean journey and let me tell you that was absolutely the leanest facility I have ever seen. Great job Fastcap.
Thanks! We still have a long ways to go! #neverstopimproving
Congratulations. Fantastic example of the use of Lean principles and having an organization with people with Lean mindset. Excellent work!
Michael E. Gerber would be so proud of your company. Good job.
+Manufacturing America Thanks!
Kool video showing Lean Manufacturing in action. Thanks for sharing. Lots of good ideas here.
Paul, awesome video and great memory. Seems like we are there all over again. Every inch of FastCap is magical, thanks. You are my true north.
take care, John
John, the notion that we can collaborate and work together to improve the world is very gratifying. I view us as a team all working to the same goal! Paul
Amazing facility. Everything has a fast and efficient flow right down to their "KNUJ" isle.
This plant looks amazing congratulations it takes a lot of work and team effort. Thanks for sharing
Good job there, although, I'm not sure about the switches, I think there is a thin line that divides where to look for efficiency and it is when you lose focus on the element's functions and prefer to use another reference like the red lines in the case of aircraft switches; I mean that the tendency becomes preferring avoiding time waste and reasoning after instead of reasoning quickly, so you understand what you are doing first.
Amazing... This is one of the best examples of lean production system I've seen.
Wow, thanks Amel. But we have a long way to go. We are just babes, when it comes to Lean!
I very recently got promoted to an Engineer (I started in the factory as a temp production line worker, just loading PCBs into a conformal coat machine). The key point I saw here is having your Engineers in the production area!. This is a fantastic idea!.. as a production line worker it was easy for me to notice ways to improve processes, but the engineers were in the complete opposite end of the building, making it REALLY hard to get those inefficiencies rectified. I've been fighting (and slowly winning) in really trying to improve communication between engineering and production sides of the business. But Physical proximity seems to be a great idea. If you don't hide the Engineers away in an office at the end of the building it can help the flow of feedback.. really get the Kaizen process to flow much faster.. I'm still a very junior engineer (so much to learn every day) but I just LOVE to learn. and more than I love to learn I love to improve processes that are totally arse backwards and fix them... I hate to hear "But that's how we've always done it" and am really trying to change the culture to abandon that kind of thinking. EDIT FROM HERE: Your plane system.. fantastic. An aviation buff myself I love this idea of unambiguous switch positioning, Very 'Airbus' Philophosy. The airbus philophosy being ALL switches should be in an identical visual state when in the 'correct' position.
Most facilities keep engineers out of the production environment (in many cases lock and key) because they typically cause more harm than good.
It's been 3 years since you posted this comment. How's it been? Were you able to affect more positive changes to process efficiency?
Thanks for the training lesson for lean manufacturing, I already listened to your book a million times before it sink in my brain
Thanks Reginald!
Amazing video showing off the power of lean manufacturing.
wow, just amazing lean manufacturing. Great creativity for all the 6s tool holdings. Been working on the place I work at to even start with any of this, but I still cant even get a Bidet for years like yours.
I noticed your floors are concrete. Over time standing and walking on such a hard surface wears on the body. Back and knees are affected and can do long lasting damage.
Precisely. As someone with lifelong flat feet which are finally giving me grief as I'm about to hit 40, standing all day would kill me!
Especially a company like this when they have a standing only policy and you can't sit down to take a quick break while working at your computer to gather yourself. I'm sure they have chairs in their break room but having no chairs at their actual work area, that's kind of ridiculous. I personally prefer to stand while working at my computer but atleast my company gives you the option. We have computer desks that you can lift so you can stand while working on your computer or recline it so you can sit at your computer because standing in one spot all day will wear your back and heels out.
This is just downright stunning. Unless you've worked in a real rat hole, it's hard to appreciate just how awesome this is.
Hi Paul, you took us on a quick tour some months ago of your new facility whilst I was doing some business with Bob Lodder. Really appreciated your time then and really appreciate this video that I'll share with my managers. It really is amazing what you have done and many thanks for sharing once again.
Hey Colin, thanks for sharing. That really means a lot to me. And good to know your are passing it along so others can be inspired, too! Paul
Great information share! Enjoyed seeing examples! At 4:12 there is a lot of inventory being shown on shelves. Not sure the process - just caught my eye. Thanks!
I am Vietnamese. And I so happy when saw this clip.
I aslo want to learn Lean Manufacturing. So greats.
Thank you so much. I want to see more clip.
Check out my website (paulakers.net/) and sign up for my eBlasts (bit.ly/FastCap-Subscribe
) for more Lean information.
Enthusiasm City ! ! !
I love your creativity, Paul, well matched to your energy and laser-focus. Plus, bidets in the restrooms! What more could an employee ask for?
Sid Moore lol thanks Sid!
Its one thing to put a lot of effort into the product you make, but to hold the facility to the same standards is impressive.
Thanks for your kind words!
this video shows the incredible importance of a leader understanding of Lean
Jackson thank you!
Don't be ashamed of waste. Waste is strategic. Waste can smooth flow. I like your improvement program.
It will be a miracle for me to work here for a day. I love the process. Very magical ❤️❤️
I work in a floor manufacturing plant and is hot and fast paced. Imagine working in that and over 30 degrees Celsius outside. Not so magical
Now I know why your products are so awesome. Starts with great facility and happy employee.
Thanks Kelly. That means a lot to me. Paul
Easy of access, and three Big Ass Fans! While I don't understanding the standing, I can appreciated the 'U' format that allows the processes to flow with extreme ease. Yes-Haw!!!!
@user-xh6ro1mi1c We are allowed to sit and we do have access to chairs if we want them.
I’ve been standing full time for 2 years, often 12 hours a day. Of course I sit at breaks. But I own the company and was the first to do it before my team. We have anti fatigue mats. I would never go back to sitting. Not a chance.
Really impressed. I'm sure the many efficiencies have many benefits including quality service, staff motivation and maximum sales. Well done to Paul and all the team. This is a great example of the importance of Leadership nurturing a Lean culture and staff buying into the philosophy.
Thanks Margaret!
Paul! I loved this video! Being a maker/inventor/fabricator... You look like a fun cat to hang out with... Having things organized in your warehouse and having it all super clean is a lot of work but it truly makes for a more enjoyable ride on the scooter when you don't slip on dust bunnies... Loved the scooter mods they did to their scooters...... For sure looks like a fun place to work.... -Brian
Lean in action...Brilliant. Well done guys. We can all learn from this
cy Keogh Thanks Cy. Love hearing this!
What a great new facility and superb examples of lean concepts. I love it Paul.
Thanks a lot Chess. Means a lot to me! Paul
The color coding by days of the week to see and measure flow and if you are on time is a good idea. The simple things like that and the toolboxes to have the shadow cutouts make it easier for work flow and the ability to be agile and others to substitute in and know where things are.
What an amazing operation. The new location is very sweet. I've served packaging equipment at both the old and new location and I'm extremely impressed. The employees are extremely friendly and a pleasure to work with and you can tell they love what they do. Coming from a hobbyist woodworker I love what there doing and am not ashamed to admit to drooling a little when I visit.
+Darrin Larson Thanks Darrin...you are too kind!
It's crazy how they took away sitting. This is a high functioning plant without any non-value adding steps. It's so efficient, a person on their first day can print out so many levels.
Immaculate is the right word! Wonderful guys! love your work style.
Thanks Veronica!
I think the most important thing that this company does is 3S for a dedicated 15 minutes every day. It's not a ton of time taken from the overall day, but it is enough time to insure that everything is clean and organized, every day.
Such an awesome warehouse. Thanks for the tour.
Thanks!
Love your layout and commitment to lean!
That's fantastic and incredible! So inspirational! Do you apply the Kanban method? Thank you!
@Have a nice time! Yes we do apply the Kanban method. Check out this video:th-cam.com/video/Levkx8f0qL4/w-d-xo.html It shows all our Kanbans that we use throughout the facility.
@@FastCapLLC Thank you very much and all the best in the wolrd!
Good job guys ! I am sure that people which working there are happy and proud.
Thanks Michael!
Thanks for sharing! Lots of great ideas to share with our company! Also, it is fun to see that we are already doing some of these things.
Thank you so much for share us your amazing factory. It was very instructive, well done!!!
You are very welcome!
Congratulations you all have done a great work, I am a quality engineer and I appreciate when everyone works as a team to keep everything organized, clean and a good work flow, this as you mentioned it keeps everything smooth, enjoy to work, less waste of time. If you ever need a QA let me know lol!
Thanks, Felipe!
wonderful video started Lean at my present employer our biggest problem ....waste ,time management and no standard working procedures .
Awesome lean plant tour video! Loved it!
Thanks Tony. I'm already getting a lot of feedback! Paul
If you all ever open a facility in Reno, I'll be the first to apply!!! It looks so much like home that I'd relocate in a heartbeat if you were only in a sunny place!!! 😍😍😍Seriously, my fantasy workplace!!!!
so amazing how we can save so many times and confusion by implementing all these techniques, marvelous
Awesome! I wish I will work in a place like this some day! I dont have words, it must be really motivating towork like this! I havent seen a company like this before...
Greetings from Germany ;)
+Telias Thanks so much. Check out my website for a bunch of lean information. paulakers.net/ Also, I though you might like this video. th-cam.com/video/DhRjlIkj2Nw/w-d-xo.html
Very impressed. Hope you guys are still doing well.
This video is a great way to show how lean can be applied to any industry and way facility in their own way. I loved how the concepts of lean and six sigma were applied to different areas of the facility and processes.
Beautifully. With thanks from Ukraine
Thank you so much for uploading this video. I am currently implementing Lean at my new office and we are loving it. However, I wanted to view others to see what fantastic ideas they have come up with that we hadn't. Thanks again, this is great.
You're welcome. You should subscribe to by weekly 2 Second Lean email. I pick a video each week to share...either from me, FastCap or one that was sent to me (make sure you scroll down and select 2 Second Lean) bit.ly/FastCap-Subscribe
On the topic of scooters: This may be a silly question...would employee's need to sign a waiver before using a scooter? This way if employee's fall and bump their necks, as an example of injury, you won't be help liable for workers compensation due to on-site injury? Overall, the scooter in my opinion is perfect to use in your large facility. Thanks.
One thing I've noticed about Lean is that it has to be a company culture. You can't think, "that's a problem for someone else." You also can't have a situation where you feel like your work is wasted because the next guy in line is going to mess everything up. For instance, if 1st shift sees a shelf that needs to be organized, does so and then the next morning they see that second shift made a mess of the shelf, they feel a sense of defeat. Why would I make improvements if they're just going to be undone?
The other problem is managerial misunderstanding of the concept. Many companies think that never buying needed tools, spending money on maintenance or taking time now to improve efficiency for later saves them money, so that must be what Lean is all about. What they don't realize is that money saved in the short term is often money lost in the long term. They'll offshore their production resulting in long lead times and inventory excess when it finally arrives, pay bottom dollar leading to employees who are under qualified and high turnover rates, use the phrase "that's how we've always done it" (I hate this phrase. Never say this.) leading to stagnation, neglect the brain power of their workers leading to dissatisfaction, fail to upgrade and improve, and when they do finally have no choice but to replace something, they seek the cheapest rather than the best for the process leading to lost opportunity due to down time and inefficiency.
When I first hired onto my current company, they talked about improving efficiency and wanting to implement Lean concepts. Now that I've worked there a few months, I can see that they don't understand what needs to be done. I have made several suggestions for improvements and all have been dismissed. I have made several requests for more efficient tooling and all have been ignored. So I've decided that I need to step up or move on. I'm working on several proposals for equipment, technology and processes that will greatly improve efficiency/productivity.
This post is getting long, but I developed a little example to show how small savings end up big over time: 9 seconds = 65 hours. If you make 100 widgets per 8 hour day that means it takes 4 minutes 48 seconds per widget. If you find some way to improve that by a mere 9 seconds per widget, you gain 65 hours of extra production per year. 9 sec times 100 widgets times 5 days times 52 weeks = 234,000 seconds divided by 60 = 3,900 minutes divided by 60 = 65 hours. 1 week, 3 days and 1 hour of production you didn't have before. That's an extra 812.5 widgets per year and if you make $10 profit per widget...$8125 from nothing more than making a 3% improvement to the process.
Seems your video from 8 years ago about putting wrappers on adhesive kits demonstrates the example perfectly :P
Good points.
Kenneth,
I just started a new job as a Manufacturing Engineer/Process Optimizer with very similar issues to what you've described. I'd love to hear how things went for you, if you have the time. Your comment mirrors a number of my thoughts on the difficulties in applying changes to non-machines. : )
"A minute you struggle, you have waist". Awsome!
Paul, seriously ! Thanks for showing me the ins and outs of the Fastcap facility. This give me more respect for Fastcap. I wish the company I worked for would adopt the Lean process. My wife is a Green belt and I tried to adapt some of the Lean process at my work place….and came across some less then willing bosses. Continue to grow…50,000 square feet…..ALMOST the size of my hobby woodworking shop……LOL Just kidding…that place is HUGE! Eric
Thanks Eric. I send out a weekly eBlast on lean. Usually videos I create or others have shared with me. Some of them are folks who struggle with bosses who don't understand. Here is a link to subscribe (select 2 Second Lean). fastcap.us1.list-manage.com/subscribe?u=4b6cd3052005adbfe263c045e&id=8c1f8244f9
Keep me posted on your lean journey!!! Start small! Paul
I wish my very existence was this organized! Amazing!
I still feel that way after years of Lean. Small steps every day. Just pick one improvement and go from there! Share before/after videos, too. It will encourage you to keep going!
Love your videos.. what about working and safety between the racks? is that no an osha violation?
Cool video... if I were to guess he constructed that warehouse with Lean on his mind. To get a warehouse to that state after it has been built would be rather difficult and costly. But designing a warehouse with Lean in mind would/could make all the difference.
Very cool factory and Lean to the core. Looks like a great work environemnt.
Its alot of work to make everything easy. Nice system you have there.
Yes, it is. Thanks!
I love everything you have going on! I have tossing the idea of moving up there and applying for a job. Now that I see you have a jet I could put my A&P skills to work! If only I didn't have time remaining in the AF
+discguyjoe Thanks so much. I've sold the jet, but if you are still interested when you finish up in the AF, send me a video resume. paul@fastcap.com
Awesome company. I've been buying their products for years, had no idea what it was like behind the scenes.
So cool thank you!
very nice video, its great for learning, i have few question , 1. How to sustain the floor? 2. how change mindset of people and make them understand to achieved this lean faster? 4. can you guide me on soap factory how to do lean?
@msnit1988 Here is a message from Paul! Thank you for all the questions, All this information will be able to help you get started on your Lean journey.
Our new app called “2 Second Lean Play” has all my books and resources in audio just like The audible app. But everything is FREE..
It even has the classic books that we have recorded "Today and Tomorrow" by Henry Ford (you would swear you were listening to Henry Ford) and “The Toyota Production Handbook” by Taiichi Ohno.
We have noticed that not everyone is predisposed to personal development so we wanted to create a platform that has no barriers and zero cost so everyone can easily start their personal development journey to improve their life and their work.
We are also getting other authors to make their books available.
This project was the vision of Tom Hughes from Ireland. Tom took the ball and ran with it and develop the app and his team did a spectacular job a million thanks Tom.
Here is a quick overview videoth-cam.com/video/QxB-oAsNpFI/w-d-xo.html
Here is the link on the App Store apps.apple.com/gb/app/2-second-lean-play/id1503694993
For the ANDROID. Here is the link play.google.com/store/apps/details?id=com.leanplay
my first app is great for tracking all your daily habits here are the details
Lean PD at iTunes
Lean PD at Google Play
Paul has created the Lean PD App as his simplfied version of the Harada Method. For more information on this App, go to iTunes (bit.ly/LeanPD-iPhone) or Google Play (bit.ly/20WhCeP).
Paul has created the Lean PD App as his simplfied version of the Harada Method. For more information on this App, go to iTunes or Google Play.
Thanks
Paul
Absolutely great. Very organised. Thanks for some tips in the video.
+Jimmy Nel Your welcome!
Awesome, learning a lot from this vedio.
so crazy !!! the best way to love our work !
@fastcap I would love to see more of that auto kickstand on the right side (step on version) I love that idea.
Thanks Steve!
Hi Paul, Great tour! I love the way the your facility is set up and how variable processes flow through it. I think every day how we can achieve that in our company. Keep up the good job and thank you so much for sharing the great innovative ideas of your team.
Steve K. Spokane Wa.
Thanks Steve for your encouraging words. I highly recommend taking before/after videos. I'd love to see some. Paul
Team involvement at its best.
Prakash Shilagani Thanks Prakash!
Wow. Really makes me want to keep organizing my workshop.
Love hearing that. Make sure to make before/after videos and send them my way! Check my website for additional Lean resources. paulakers.net/
Absolutely Amazing , To think how many years it's been that I've been doing biz with Your company. And Look how big You guys have grown. Best part is That Lean Mfg . without it You guys would need 10 times the space. Fantastic Paul, Lean Manufacturing at Work! a picture is Truly worth a Million words. Thanks Joe
Thanks Joe!
Great presentation, teamwork, time saving caps.... but i feel like there's still a room for improvement (work flow, inventory and so on). For example small spaces between the aisle what is consuming space, where is JIT?
You're so right. There is ALWAYS room for improvement!
Cool little video! I really like that lean detail with the plane switches.
Los felicito por sus preciosas instalaciones y sus productos mi pregunta es. no utilizan paneles solares para bajar costos de su precioso edificio ?
Not at this time, It’s not viable with the amount of sunlight that we get (or I should say, don't get)!
I worked at walmart through college and I can tell you that standing on concrete for 8 hours will destroy your body regardless of foot wear
Completely agree, I feel that flexibility should be added to allow the workers to stand or sit, tables that adjust in height
100% agree. While standing may improve some worker(s) attentiveness and promote other health benefits, it is not always the optimal solution for all employees. I have had a few spinal procedures that would prohibit myself from standing 100% of the time. There are flexible desk options these days. Think HumanScale or FlexDesk. Very informative video. Great lean concepts. The Big Ass fan is highly effective and works everywhere I have seen them.
@@toddcutsuries54 for some reason customers feel like a cashier sitting on a stoll makes them lazy or something and alot if those same people would never allow themselves to be subjected to that
Having done actual work at a facility similar to this design complete with a no-sitting policy, it is GREAT! Sure, it is rough for a while until your body gets used to it, but it is so much better for you than destroying your back with terrible sitting posture (I'm certain that only people with excellent posture will reply. Hear the sarcasm?).
However, for people with a medical condition they DO make exceptions. There is always an absolute difference between a WANT and a NEED.
Having also done grocery-store work, I can share this: In a place like Walmart it is a VERY different scenario. If you are a cashier then you are STABLE and standing (ie: unnatural standing) which can get you very sore easily. And if you are stocking then you are constantly bending and lifting items and most people have terrible lifting posture which will also ruin their body.
Finally: This is how work has been done throughout history. Being able to lounge in your chair at a computer desk is a modern convenience that lets you destroy your back with terrible posture daily. I personally HATE how much pain it causes.
Yup. Mandatory standing desks are cancer
Congrats! What a marvelous factory.
Still I'd like to know what's the purpose of having no chairs, the flexibility or to keep the workers awake maybe?
Thanks Ignacio! Here is a video I made on the benefits of using stand up desk. Hope it helps. th-cam.com/video/1t4ntpa7MME/w-d-xo.html
Amazingly organized. Perfect Gemba. I wish I could get a job here🙂
You guys are amazing. Keep up with the good work.
Marko Orosnjak Thanks Marko!
thanks for the best way to work
this area has everything my employees have ever asked for, from scooters, to auto pallet wraps, to free food. But it makes me wonder what was the cost to get them there?
Fastcap you guys are amazing and inspiring great job!!
+Northwest Die Casting & Manufacturing, CNC Machining & Metal Finishing Thanks so much!
Can you tell me what the brand and model is of the automatic pallet wrapper is? I can't seem to find any like that particular model.
I'm a new subscriber and am enjoying your videos. You have a great workplace. The morning meetings are great for keeping everyone focused on the company's mission statement. Also, I believe allowing a different person to be the leader is great for self confidence, and if you're not used to speaking in public, it's a great opportunity in front of your peers, who don't want to see you fail, but to improve. When everyone knows how the company functions, how decisions are made, you as an owner, can feel assured that when you're on a trip, you won't come home to a disaster. Also, you could pick anyone from your group to give a tour and they'd be able to show and explain to visitors how everything works, and answer just about any question. Thanks for sharing.
Ron Briz Thanks Ron for you nice comments and good insights!
Hi Paul, I'm a Question, How do you to manage Cutting Tool Inventory in your Shop???