Round 1 Debrief - AM What worked? What didn’t work? – Inspection standards missing – Rework missing proper tooling – Bottleneck at inspection – Shipping is a bottleneck – Layout is inefficient – Need some line-balancing, leads to poor quality – Sail forming difficult, need training – Production schedule vs. sales, production schedule imbalance – Boxes need to return to shipping – Inventory….Do we need that much? – Fail individual batches

Changes for Round 2 Consider the following: – Factory Layout Put tables in a line, eliminate WIP locations Eliminate bubba? Re-assign to real work! Other? – Point of Use Storage (POUS) Batches? Store paper at folding – Line Balancing How many folders do we need? 3? 4? Flexing work Split fold 2 into 2 operations Combine stamping and oven Training for stamping – Poke-Yoke, Quality at the Source Sail height Stamp location (centering)

Round 2 Debrief - AM What worked? What didn’t work? – Better! – Excess employees. Optimize. – Still too much work in folding? – STOP PUSHING!?!?!?!?! – FLEX work? – Self inspection? Inspection during the process?

Changes for Round 3 Consider the following: – Factory Layout – Pull System, Kanban Pacemaker process? Shipping Kanban size? – Continuous Flow and Supermarkets Supermarkets before and after oven? Folding and stamping into continuout flow Fire production scheduler – Poke-Yoke, Quality at the Source Inspection along the way Sail height – can be reworked Stamp centering

Round 3 Debrief - AM What worked? What didn’t work? – Final Kanban = 4 worked well – Continuous flow and flex (minimal flexing) – Some flexing in first folding op – Inspector helping with oven batching – Folding much improved Areas for improvement? – Need more sales to make money – 1 hour day sales forecast