BCMC

The Path of Least Resistance: A Lean AnalysisSpeakers: Greg Griggs, Builders FirstSourceBJ Louws, Louws Truss, Inc.

Program handouts sponsored by:

The Path of Least Resistance:

A Lean Analysis

Greg Griggs | Builders FirstSource ▪ BJ Louws | Louws Truss Inc.

Motion Analysis• RT-1 & RT-2

• Floor Line

RT-15,109 board feet in 8 hours• 2,710 unnecessary steps

• 64 to pull saw• 50 to chop saw• 190 to linear saw• 260 to plate rack

RT-24,734 board feet in 8 hours• 1,774 unnecessary steps

• 34 to pull saw• 68 to chop saw• 140 to linear saw• 206 to plate rack

RT-1 & RT-2Causes of unnecessary steps:• Mis-cuts/recuts

• Lumber stacking from saws

• Pulling carts to table

• Location of drinking water

RT-1 & RT-2Causes of unnecessary steps:• Mis-cuts/recuts

• Lumber stacking from saws

• Pulling carts to table

• Location of drinking water

RT-1 & RT-2Causes of unnecessary steps:• Mis-cuts/recuts

• Lumber stacking from saws

• Pulling carts to table

• Location of drinking water

RT-1: BEFORE•5,109 board feet in 8 hours•2,710 unnecessary steps

RT-1: AFTER•6,546 board feet in 8 hours (28% increase)•400 unnecessary steps (85% reduction)

RT-2: BEFORE•4,734 board feet in 8 hours•1,774 unnecessary steps

RT-2: AFTER•5,302 board feet in 8 hours (12% increase)•718 unnecessary steps (60% reduction)

Floor Line

Causes of extra steps:•Pulling plates and webs•Location of shop drawings and drinking water

4,300 board feet in 8 hours• 1,894 unnecessary steps

• 42 to pull saw• 92 to chop saw• 100 to linear saw• 226 to plate rack

Floor Line: BEFORE•4,300 board feet in 8 hours•1,894 unnecessary steps

Floor Line: AFTER•6,873 board feet in 8 hours (60% increase)•284 unnecessary steps (85% reduction)

Motion Analysis

Floor Line

• 1610 steps saved• 2573 feet gained

RT-2

• 1056 steps saved• 568 feet gained

RT-1

• 2310 steps saved• 1437 feet gained

Motion Analysis

•Review findings and workflows

•Review missed cuts and stacking

Weekly meetings

•Eliminate machine reasons for missed cuts: train staff on PMs and calibration

•Keep wasted motion to a minimum: identify areas for new staff training

Training•Material handler job:

improve staging and reduce downtime between batches

•New assignment: clean, fill, and stage water coolers every shift

Restructuring

Motion Analysis Material Handling

• One of the greatest improvements that can be made on the shop floor.

• Minimizes waste by eliminating excess movement of material (and people).

GoalsEliminate the need

for builders to leave the

jigs

Eliminate the need

for builders to sort

material

Material Handling

• …leave the build station?• Missing information (paperwork, questions)• Missing material (lumber, plates)

• …not get wood into the jig and build?• Sorting material

Why do builders…

Missing Information?Go paperless with projectors, tablets and computers

• Puts information at the point of use

• Integrates easily with most production software

• Is increasingly less expensive to implement

Missing Material?Keep plates at the point of use

• Fabricators always have the correct plates on hand

• Fabricators don’t have to leave because plates are pulled incorrectly

Missing Material?Implement Kanban and staging

• Color-code carts for work-in-process Kanban• Sawyers see which stations

need material• Fabrication “pulls” from saws

• Create staging areas for cut material near the workstation

• Improve changeover efficiency to reduce batch sizes and sorting

MissingTools?Keep tools at workstations• Identify the tools needed at

each station

• Shadow board tools and label them appropriately

• Implement at all workstations to ensure tools stay where they belong

Paradigm Shift:Just-in-time Cutting• Reduces…

• …motion and touches by eliminating carts

• …travel time for defective material

• …in-process inventory

• Eliminates material sorting at build stations

• Makes the sawyer part of the build crew (cell)

Increases productivity!

Old system: 13 touches per piece of lumber

New system: 5 touches per piece of lumber

Please complete your session evaluation!

Greg is senior vice president of manufacturing at Builders FirstSource. He has 35 years of experience in the industry in production, design, operations, management and leadership. He is a certified Lean Six Sigma green belt.

greg.griggs@bldr.com

BJ is president and co-owner of Louws Truss Inc. He joined the industry in 2007 after earning a degree in economics and business administration at Seattle Pacific University. He started learning Lean 2009 with a grant from the state of Washington and continued developing his expertise with local seminars in 2012.

BJLouws@louwstruss.comThank you to the sponsor of this session!

© 2016 MiTek, All Rights Reserved.

YOUR FUTURE. OUR FOCUS.

Commited to your future, MiTek® is dedicated to improving the component manufacturing industry through improved effi ciency, productivity, and collaboration. We help power the growth of your business by offering you valuable assets, including results-driven software, machinery, products, our support team, and free access to MiTek University. Because we defi ne success one way: yours.

Learn more at Mitek-US.com.

MTEK_15865_BCMC_YFOF_Handout_Print_8.5x11.indd 1 9/14/16 9:48 AM

BCMC

Efficiency Essentials from the Lean Toolbox Speakers: Greg Griggs, Builders FirstSourceBJ Louws, Louws Truss, Inc.

Program handouts sponsored by:

Efficiency Essentials from

the Lean ToolboxGreg Griggs | Builders FirstSource ▪ BJ Louws | Louws Truss Inc.

Kanban

5_S

Kaizen Event

Waste Walk

Kanban

A simple, visual system to regulate inventory or work in progress in the

manufacturing process.

KanbanTwo Bin System

• Labels• Station• Plate• Number of plates

• Great for bulk product distributed to point of use.

• Ensures supply at each station.

• Very easy to train.

KanbanCard System

• Great for non-commodity goods.• Hangers• Nails• Staples• Banding

• Great for items ordered semi-regularly.

KanbanCard System

• Details• Picture & product name• Location• Vendor & part #• Min and max quantity

• Card to the re-order box when inventory is at minimum quantity.

• Card returned when inventory is stocked.

KanbanInventory Lists

• Great for handling many SKUs.• Maintenance department

• Great for items with minimum quantities of zero and maximum quantities of one.

KanbanInventory Lists

• Details• Location• Item/Description• Part #• Vendor• Min, max & order quantity

• List is laminated for dry erase marking; cleaned and returned when inventory is stocked.

KanbanControls Work in Progress

• Shop floor to vendor

• Workstation to workstation

• Changes workflow from push to pull system• Defines quantity• Defines re-order process• Creates re-order system• Reduces time• Maintains inventory

5 S

SustainStandardizeShineStraightenSort

Beams Dumpster Grinder

Before Before Before

After After After

Finished Goods

Before After

Old Tires

Before

After

Raw Lumber Storage

Before

After

Scrap Metal

Befo

re

Aft

er

Kaizen Event

A short, intense event to improve a designated area or

process.

Kaizen EventDefine the Event

• Determine the area or process to improve.

• Determine the lean tools to be used to implement process improvements.• 5 S• Kanban• TPM

• Select a Kaizen facilitator and cross-functional team.

Maintenance area

before 5 S and Kanban

Kaizen EventGet Going

• Meet up the first day to plan the week.• Create action plan• Delegate responsibilities• Go!

• “Red Tag” the area• Remove everything from

the designated area that is not directly related to the process.

Kaizen EventStay on Track

• Meet daily with the team to delegate tasks.

• Keep your team on track with daily goals.

• Give the team the power to make decisions and move forward.

Kaizen EventCloseout

• Finish as much as you can within the allotted timeframe.• Typically, one day to one

week

• Create an action item list• Tasks that need to be

finished• Who is responsible for them• When the task must be done

ACTION ITEMS WHO WHEN

SHADOWING/LABELING - TOOL BOARDS AND WALLS ( T1,T2, ETC.) JOSHUA AND RYAN FRIDAY APRIL 1ST

PAINT FLOOR DESIGNATIONS AND LINES - INSIDE AND OUTSIDE OF ROOM JOSHUA AND JUSTIN FRIDAY APRIL 1ST

RAG BIN / HAMPER FOR RAGS - BUY AND INSTALL BJ LOUWS FRIDAY MARCH 25TH

LABEL ALL BINS AND SHELVES & ESTABLISH MIN AND MAX QTY'S JOSHUA / JUSTIN / BJ LANDRETH WEDNESDAY JUNE 1ST

LABEL ALL CARTS & BINS & ESTABLISH MIN MAX QTY'S JOSHUA / JUSTIN / BJ LANDRETH WEDNESDAY JUNE 1ST

AIR TOOL / NAIL GUN RELOCATION BJ LOUWS / BJ LANDRETH WEDNESDAY JUNE 1ST

ORDER FLAMMABLE CABINET JOSHUA FRIDAY MARCH 25TH

POPULATE FLAMMABLE CABINET / LABEL / SET MIN MAX QTY'S JOSHUA / JUSTIN FRIDAY APRIL 29TH

RED TAG - OVERSTOCK LIST - ORAGANIZE/CATEGORIZE - PUT UPSTAIRS JOSHUA / BJ LOUWS / CLARENCE FRIDAY APRIL 29TH

RESET 5S CART JOSHUA FRIDAY APRIL 1ST

TOOL CHECKOUT CARDS & LEGEND RESET PROCEDURE / PICTURES / EXSPECTATIONS

JOSHUA / JUSTIN / BJ LOUWS FRIDAY APRIL 1ST

MAINTANCE ROOM OREIENTATION TO COMPANY BJ LOUWS WEDNESDAY JUNE 1ST

Kaizen EventTrain

• When all of the action items are complete, train staff on the new process.

• Great implementation with no training is a set up for failure.

• Schedule the next Kaizen event.

Waste Walk1. Defects

2. Overproduction

3. Transportation 4. Waiting

5. Inventory

6. Excessive Motion

7. Excessive Processing

8. Underutilized People

• Find waste• Take notes• Take action

Identify any activity that adds cost but not value to the

product or service you offer

customers.

Standardized Work Instructions

Draw a pig

In profile, facing left, centered in the 3x3 grid.

Large enough that you use some part of every box except the top right.

In two minutes.

Standardized Work InstructionsTask Description Sub-Task Instructions

1 Draw a letter M at the top left intersection 1.1 Bottom center of M touches intersection2 Draw a letter W at bottom left intersection 2.1 Top center of W touches intersection3 Draw a letter W at bottom right intersection 3.1 Top center of W touches intersection4 Draw arc from letter M to top right intersection5 Draw another arc from top right intersection to bottom right W6 Draw an arc between the two bottom W's7 Draw the letter O in the center left box8 Draw arc from letter M to tangent of the circle9 Draw arc from the left W to tangent of the circle10 Draw an arc for the mouth 10.1 Half way between the W and the circle

10.2 Must be a happy Pig11 Draw an arc for the eye 11.1 Half way between the M and the circle12 Draw cursive letter e near top of arc on right

Standardized Work InstructionsTask Description Sub-Task Instructions

1 Draw a letter M at the top left intersection 1.1 Bottom center of M touches intersection2 Draw a letter W at bottom left intersection 2.1 Top center of W touches intersection3 Draw a letter W at bottom right intersection 3.1 Top center of W touches intersection4 Draw arc from letter M to top right intersection5 Draw another arc from top right intersection to bottom right W6 Draw an arc between the two bottom W's7 Draw the letter O in the center left box8 Draw arc from letter M to tangent of the circle9 Draw arc from the left W to tangent of the circle10 Draw an arc for the mouth 10.1 Half way between the W and the circle

10.2 Must be a happy Pig11 Draw an arc for the eye 11.1 Half way between the M and the circle12 Draw cursive letter e near top of arc on right

Please complete your session evaluation!

Greg is senior vice president of manufacturing at Builders FirstSource. He has 35 years of experience in the industry in production, design, operations, management and leadership. He is a certified Lean Six Sigma green belt.

greg.griggs@bldr.com

BJ is president and co-owner of Louws Truss Inc. He joined the industry in 2007 after earning a degree in economics and business administration at Seattle Pacific University. He started learning Lean 2009 with a grant from the state of Washington and continued developing his expertise with local seminars in 2012.

BJLouws@louwstruss.comThank you to the sponsor of this session!

© 2016 MiTek, All Rights Reserved.

YOUR FUTURE. OUR FOCUS.

Commited to your future, MiTek® is dedicated to improving the component manufacturing industry through improved effi ciency, productivity, and collaboration. We help power the growth of your business by offering you valuable assets, including results-driven software, machinery, products, our support team, and free access to MiTek University. Because we defi ne success one way: yours.

Learn more at Mitek-US.com.

MTEK_15865_BCMC_YFOF_Handout_Print_8.5x11.indd 1 9/14/16 9:48 AM