Lean Manufacturing - Lean Factory Tour - FastCap
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- เผยแพร่เมื่อ 8 ก.ค. 2024
- (Get More LEAN at) paulakers.net/
Are you interested in Lean Manufacturing? Well take a trip to the shop floor and see a lean factory tour at FastCap in Ferndale, Washington.
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Paul Akers is an entrepreneur, business owner, author, speaker, & Lean maniac. He has written multiple books on Lean and travels the world to educate, speak, and mentor Lean principles, Lean manufacturing, and Lean living as a lifestyle. Paul has a weekly podcast called The American Innovator where he shares about Lean & his travel adventures. For more information on Paul Akers and Lean, visit his website. paulakers.net/
For more information on FastCap, visit FastCap's website. www.fastcap.com/
To sign up to receive news regarding FastCap, 2 Second Lean, and The American Innovator podcast, go to this link: bit.ly/FastCap-Subscribe
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What an amazing facility; Lean concepts from top to bottom and across all departments. "See waste, think lean!'
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.
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.
Amazing facility. Everything has a fast and efficient flow right down to their "KNUJ" isle.
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.
Kool video showing Lean Manufacturing in action. Thanks for sharing. Lots of good ideas here.
So efficient and organized. Everyone seems friendly and happy. Looks like a great place to work!
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!
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
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.
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
Thanks For showing great example of Lean including Visuals .
Great.
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. ☺️
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
Love your layout and commitment to lean!
This plant looks amazing congratulations it takes a lot of work and team effort. Thanks for sharing
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
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/
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... 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!
Amazing video showing off the power of lean manufacturing.
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
This is just downright stunning. Unless you've worked in a real rat hole, it's hard to appreciate just how awesome this is.
WOW! Very impressive. Awesome environment.
so crazy !!! the best way to love our work !
Congratulations. Fantastic example of the use of Lean principles and having an organization with people with Lean mindset. Excellent work!
Cool little video! I really like that lean detail with the plane switches.
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
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!
Such an awesome warehouse. Thanks for the tour.
Thanks!
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 !!
NEAT! looks like fun place to work..
Immaculate is the right word! Wonderful guys! love your work style.
Thanks Veronica!
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!
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.
Amazingly organized. Perfect Gemba. I wish I could get a job here🙂
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!
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
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
so amazing how we can save so many times and confusion by implementing all these techniques, marvelous
Very cool factory and Lean to the core. Looks like a great work environemnt.
Well, this is amazing!
I love your videos, they are a source of inspiration for my future occupation
Don't be ashamed of waste. Waste is strategic. Waste can smooth flow. I like your improvement program.
Awesome lean plant tour video! Loved it!
Thanks Tony. I'm already getting a lot of feedback! Paul
Awesome, learning a lot from this vedio.
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
Thank you so much for share us your amazing factory. It was very instructive, well done!!!
You are very welcome!
You guys are amazing. Keep up with the good work.
Marko Orosnjak Thanks Marko!
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
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!
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.
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!!!!
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!
WOW! I've seen a few places that can match you, a few! Outstanding and thank you so much for sharing!
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?
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.
Lean in action...Brilliant. Well done guys. We can all learn from this
cy Keogh Thanks Cy. Love hearing this!
Very impressive.
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.
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!
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
Great video and facility 👍
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!
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
Inspiring!
Awesome!!!
Beautifully. With thanks from Ukraine
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.
this video shows the incredible importance of a leader understanding of Lean
Jackson thank you!
Congratulations. This is inspiring.
I love this vid so much
Team involvement at its best.
Prakash Shilagani Thanks Prakash!
thanks for the best way to work
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.
Nicholas Niedzielski: None at all. The only thing I cared about was relieving the burden off of my people from performing the arduous task of walking around and around to shrink wrap. The new wrapper allows them to place the pallet and walk away, & come back when it's done. Meanwhile, they're performing other tasks. What is the return on investment? I have no clue and I don't care. I have a lot of happy people that work for me and that is priceless! Paul
+Robert Dailey (Dailey Woodworks) Check out this truck! th-cam.com/video/--IZsaCsc0A/w-d-xo.html
These are not the words of a boss, these are the words of a true leader. Forward thinking, for the good of their people, knowing that having such an attitude is the right thing to do AND a smart business decision.
Quick acting and innovative is the way to be. Maybe the analysis time would have saved money due to showing the wrapping machine wasn't needed. Maybe the analysis would have cost more than just buying the machine due to the increased time and effort to model wrapper use cases. Who knows. It doesn't matter.
FastCap has worked hard to gain the disposable income to make quality of work life improvements to the factory for its workers. Other company heads would have stashed that all away in profits. Save plenty for profits, sure. Here, though, that relatively small chunk of money was used in a smarter way. I hugely respect decisions like this, and even more so the thinking process behind that decision. Quick, effective, and most importantly helping give back to what all employees can rally around: a more streamlined and enjoyable job.
I'm glad I have voices like yours high up in the business world to look up to on how to lead a company in the future. It boosts my motivation as an aspiring entrepreneur to keep at the grind, knowing that others are also striving to achieve a better, more responsible way to do business.
Thanks for the wonderful and detailed shop tour. Not often do you get to see one like this of such a large building housing such a successful company. That success is clearly well deserved.
We use some of your products in our shop and this video makes me even happier to do so.
Christian
I have told people for years if it wasn't a warm weather personnel move up there and work for you. I wish all my different bosses through the years would have had your attitude.
That's an awesome factory.
+Eason Qin Thanks Eason. We have a long way to go, but we are always working on it!
Michael E. Gerber would be so proud of your company. Good job.
+Manufacturing America 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
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
I liked your working environment, everyone is happy with his/her job.👍🏻got motivated
Thanks for sharing
Incredible!
Thanks!!! Paul
Nice!!!
Working without struggling environment really makes different
wonderful video started Lean at my present employer our biggest problem ....waste ,time management and no standard working procedures .
Very inspiring!
Thanks Matthew!
STANDING TEH WHOLE DAY, CRAZY!
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!
Good job.
awesome job you have done
Thanks!
I enjoyed it. That's how the factories should be
Great impliment of 5s love from india😍😍😍
"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
Fantastic Video, cant wait to show my students.
Jonathan Schwartz Great. Thanks Jonathan!
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!
Good job guys ! I am sure that people which working there are happy and proud.
Thanks Michael!
Love it
WOW WOW!!! WOW WOW!!! WOW WOW!!! LOVE LEAN!!