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?