Mission Our Mission is to provide sufficient throughput to allow the student crafts warehouse to ship broom craft products within 48 hours from the time the order is placed . Vision Our vision is to expand the opportunities to spread the Berea message over a wider customer base to increase the circle of influence.

Charter Mission – Have sufficient inventory to ship broom craft products within 48 hours. Burning platform – There are missed opportunities to share the Berea message through relationships built upon satisfied craft customers. Process Description – Currently orders are taken and released to craft production in a make to order methodology which results in orders not shipping complete within 48 hrs. Problem Statement – The broom craft process needs to respond to customer demand and pull products through craft production. Sponsor – Derrick Singleton Process Owner – Tim Glotzbach Team Lead – Deloris Reid and Chris Robbins Facilitator – Richard Smith Team – Tim Glozbach, Deloris Reid, Chris Robbins, Jen Salyer, Charlie Gipson, and Richard Smith IT solutions around the corner?

Administrative support and training SIPOC Suppliers Inputs Process Outputs Customers Lack of Finished Goods inventory Standard work not clearly defined Availability of work students prevent continuous flow Work is pushed through the craft areas BC Student Labor BC Crafts staff Raw Material Vendors Craft labor Quality raw material delivered at the right time, right quantity, at the right place and of the right quality Administrative support and training Satisfied Customers Training of students Opportunity to share the Berea great commission Profit Individual retail customers Craft Vendors Work students Wholesale customers

Broom corn is machine wound or hand rolled onto handle Hi-Level Process Map Broom corn is machine wound or hand rolled onto handle Broom is braided if required Broom is machine or hand stitched Broom is finished

SWOT Analysis Internal External Strengths Weaknesses Opportunities Enthusiastic leadership. High percentage of returning labor students. Loyal customer base for Berea craft products. Berea craft products command a premium in the market. Difficult to manage flow around student labor force. Do not have a clear capacity/resource estimate for required production. Internal Strengths Weaknesses Opportunities Threats External Application of TOC buffer management for finished goods. Application of TOC buffer management for raw materials. Use TOC red/yellow/green signals to identify the most important work for broom craft to execute. 5S the craft area Educate the staff on TOC fundamentals. High season prevents completion of buffers before February 2014. Wholesale customers place too many customer specific requirements. Software vendor is not capable of making changes to the software to accommodate a TOC buffer report.

Gap Analysis Opportunities and Priorities Lack of inventory to ship from stock Establish finished goods buffers based on RRT. Develop buffer report with software vendor. Develop a proper signaling method for the craft area that will identify the most important work. Apply 5S and VSM to craft process.

Queue WIP Completed Establish RRT for each broom. Complete ideal future state VSM 5S the craft floor Establish RRT for each broom. Establish buffer for each broom based on RRT Discussion with software vendor for time and estimate for creating a buffer report. Complete TOC training class for all Broom craft personnel

February 2014 Buffer Report PART DESCRIPTION RRT OH ALLOC AVAIL GR-LEV YEL-LEV RED-LEV RED ORD-QTY YEL ORD-QTY 1310M Will-O-Wisp, Multi 9 13 2 11 27 18 12 16 1300 Ram's Horn Broom 7 8 4 5 1302 Cake Tester 92 3 89 180 120 60 91 1305N Roundtree, Natural 8" 62 100 50 118 1306 Cottage Broom 52" 24 45 30 20 21 1307 Cindersweep 22", 17 1 1308 San Whisk 15 10 1309 Stupa Broom 1330N Handy, Natural 35" 1350M Streamliner, Multi 52", 64 96 40 36 1350N Streamliner, Natural 52", 42 28 1607 Fireplace Broom, Black 24 33 26 19 1862 Shaker Braid, 52", 75 48 32 1872 Vaya Verde Broom 23 1305M Roundtree, Multi 8", 1310N Will-O-Wisp, Natural 6 1321 Whisk-Away Cancer 22 1325 Cobweb Sweep 36" to 48""" 54 1330M Handy, Multi 35", 53 1501M Hearthsweep, Multi 28", 1862M Shakerbraid, Multi 52" 46 38

Daily Production Report February 2014 Production Report Daily Production Report   STUDENT CRAFTS  SCHEDULE PRODUCTION Product # PRODUCT AVAIL SCHEDULED COMPLETED OVER/ NUMBER SIZE AND DESCRIPTION START Resource/Task HOURS QTY UNDER Streamliner Nat. Chris/Wind 8 10 Shakerbraid Nat. Chris/Stitch 15 Handy 7 Will-o-wisp Multi 3 Fireplace Broom Chelsea/Wind 2 Stephanie/Braid 6 4 -2 San Whisk Seth/Roll -3 Roundtree Nat. Justin/Roll 23 Kendahl/Braid 5 TRANSFER Handy Nat. Total 35

Report Out Notes As of February 2014 back orders have been eliminated. Pull system replaced push system. Inventory is available to ship broom craft products within 48 hours. Production schedule allows the students to be a self-directed work force. Freed up time to complete a LEAN 5S project. Students have completed work credit for participating and completing two lean projects. Throughput has increased 20% with capacity to absorb demand anomalies. Potential to pursue additional wholesale customers.

Project Team