Kaizen FastCap Style (2P-10) Work Cell Development
An extraordinary example of how kaizen can radically transform a production work cell by eliminating motion, simplifying the work, and promoting quality.
Motion
LeanBNB: The Advantages of Designing Small Work Cells
It is smart and “lean” to challenge yourself to use less space. This is especially the case with work cell design. Smaller work cells require less walking, less motion, are less expensive to operate, and force you to “keep the rope tight.”
LeanBNB: Setting in Order in Bellingham
See how “set in order” (straighten) applies to an AirBNB kitchen. Lean is about more than just organization and looks. It’s also usually a bad idea to hide things behind doors or drawers. Instead, make the organization visible and accessible!
The Waste of Motion at Seating Matters
Understand the waste of motion and why it is non-value added. Also see a recent improvement at Seating Matters that has eliminated lots of needless motion.
One Piece Flow in a Finishing Room Example
See this well demonstrated and explained application of one piece flow in a finishing (paint) room in a cabinetry business. Converting from batch to flow might be a mental block at first, but yields amazing results when perfected!
Envelope One Piece Flow Simulation at Gemba Academy
See the difference between batching (over production) and one piece flow in this envelope stuffing simulation performed by Gemba Academy. Over production increases both motion and inventory wastes in this example.
Nut & Bolt Assembly Improvement at Seating Matters
Watch the power of continuous improvement reduce wasted motion and the risk for defects and over processing at Seating Matters. A simple jig makes the work faster, safer, simpler, and higher quality.
The LEAN Donut Shop! Lean Documentary | Episode 1
We introduce the Lean Donut Shop and take you to the donut kitchen where we expose employees to the concepts of VALUE and WASTE for the very first time! You will discover the 8 wastes of lean, define “value,” and realize why respect for people is foundational for building a lean organization. Learn with us at the gemba with real examples, spontaneity, and humor!
10 Kaizen “2 Second Lean” Improvements in 4 Minutes
Discover our 10 latest “2 second lean” kaizen improvements at home in the spirit of Paul Akers. Show others how simple and fun it is to do lean!
Lean Kitchen Pots and Pans Kaizen Improvement
See how straighten from 5S helps to eliminate frustration and waste–even in the kitchen! We reorganize the pots and pans so they are easy to access and visually easy to find.
Lean Manufacturing One Piece Flow vs. Mass Production Paper Airplane Simulation
See how to transform slow and wasteful mass production into lean one piece flow in this simple and fun paper airplane simulation. Witness how one piece flow eliminates many wastes that are otherwise common to batching.
Hands-On Toyota Tour and Kaizen | Derby
Short mini documentary of touring Toyota and participating in Toyota-style kaizen.
How Lean Works in the Office by Ryan Tierney
See many ways that the Seating Matters team applies lean to office processes in Accounts Receivable. From simple automation, digital and physical 5S, to kanban and more!
Lean Sprinkler System | Amazing 5S & Standardization
See how immediately standardization can eliminate loads of waiting, confusion, and struggle in this before/after sprinkler system improvement. Lean is visual! And it is meant to be simple.
TPS Applied to a Food Distribution Center
Watch a few Toyota employees apply the Toyota Production System (TPS) to a meal packaging line supporting food distribution after superstorm Sandy. They take the pack time from 3 minutes to just 11 seconds!
One Piece Flow Cell Developed at Wildwood Cabinetry
See a series of 30+ small “2 second” improvements (aka kaizen) at FastCap as Paul Akers practices the essence of what is known as 2 Second Lean.
Work Cell Development and Basic 5S at Pitt Meadows Plumbing
See a work cell design transformation after applying basic 5S principles to straighten and standardize the work at Pitt Meadows Plumbing.
11th Finger Process Improvements
See kaizen improvements to the 11th Finger work cell at FastCap to eliminate motion, struggle, and boost safety.
FastCap Improvements Reel 2014
See the FastCap improvement reel for 2014, compiling the best and favorite improvements made by employees throughout the year!
2 Second Improvements on the GlüBot Line
See two improvements to the GlüBot work cell at FastCap–both great examples of simple 2 second improvements. Also hear Paul explain the four criteria he teaches for evaluating improvements: safety, quality, simplicity, and speed.