1. 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.

2. 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?

3. 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

4. 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

5. 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.

6. 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.

7. 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

8. 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

9. 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

10. 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.

11. Project Team