Round 1 Debrief - PM What worked? What didn’t work? – Bottleneck at folding – Bottleneck at shipping and inspection – Inspection: sale height, stamping location, wild stamping, uneven folding, scraping – Couldn’t meet sales for silver boats, glut of gold boats – Sales and production scheduling not matching – Inefficient material handling

Changes for Round 2 Consider the following: – Factory Layout Move folding tables together? And stamping? – Point of Use Storage (POUS) Get rid of kitting, move workers to folding, use POUS at fold1 – Poke-Yoke, Quality at the Source Have folders inspect work? Send rework only individual boats, not full batch Inspection/rework before the oven – Line Balancing Inventory build-up detrimental to quality Get rid of kitting, move workers to folding Move workers around

Round 2 Debrief - PM What worked? – Better factory layout – Boat quality down – Bad stamping – Need Poke-Yoke – Sail template worked well in inspection and folding What didn’t work or should be improved? – Inspection – move to source, self inspection – Not enough silver boats: orders not same as schedule

Changes for Round 3 Consider the following: – Factory Layout Flex work – Pull System, Kanban Pull between station – Continuous Flow and Supermarkets Supermarkets around the oven (monument) – 2 gold, 2 silver Kanban Continuous flow – Poke-Yoke, Quality at the Source Inspection at source

Round 3 Debrief - PM What worked? What didn’t work? – Quick communication of demand – Let us respond to demand mix – Less stressful at each process – Might need Kanban adjustment – increase? – Flex workers – more balance – Less WIP Areas for improvement? – Larger Kanban – Time study in folding, line-balancing, flex working, work cell – Layout improvement – Another stamp tool? Another oven?