FVTC: The LEAN Movement

Jessica Van Dyn Hoven

Support Specialist – Printing Services

Fox Valley Technical College

Appleton, WI

LEAN Overview

• Introduce staff to LEAN

• Demonstrate how Value Stream Mapping (a LEAN Tool) can be used to identify and reduce waste in our work environment.

Value Stream Mapping (Current State Map)

Yellow – Customer Input

Green – Process

Blue – Delivery Locations

Pink – Areas of Opportunity

Problem Statement

Printing Services has 2 delivery times per day:

11:00 am and 3:00 pm.

Currently, the delivery driver believes he meets that expectation only 20% of the time.

Target goal 90%

Action Planning - Fishbone Diagram Manpower/People

Methods Machine/Equipment

Materials • Filling in for others

• Overextend

• Commitments

• Other duties as assigned

• Waiting on Team Members

• Miscalculating Time It Takes to

Complete Project

• Phone calls

• Check in with Teammates before Leaving

• Leaving Materials in Truck

• Running out of Paper

• Wheels on Cart Get Frozen

• Frozen Overhead Door on Delivery Cart

• Restocking paper on shelves

• Restocking Pallets

• Watch Work Study People • Rush Orders Incomplete

• Other Materials Left in Truck • Boxes on Delivery Cart Not Labeled/Improper • Boxes not sorted on Cart Accurately • Shipments Delivered to Wrong Area • Unexpected Stops

• Clean Out Paper In Copy Center • Pick Ups • Added Delivery Times • Too Many Hand Deliveries • Filling out Mileage Log is Incomplete • Gas Processes Not Being Followed • Marking Orders as Completed Even When They

Have Not Been Delivered

• Manually Lift Dolly In and Out of Truck

• Shipping and Receiving Gates Locked

• No Where to Store Materials

• Can’t Use Proper Doors

• No Keys to Use the Pallet Jacks

• Moving cart through Hallways of People

• Lift Up Chart-Too Noisy

Late deliveries

Team Decision Making Meetings

• Created a working action plan document

• Assigned ownership, priority and due date

Just Do It!

Results • Improved accuracy of delivery times from 52%

to 92.5% - exceeding our goal of 90% accuracy!

• Collaborated with the Shipping/Receiving to gain access and share equipment.

• Reduced the number of stops for our delivery driver from 21 to 9.

Team Celebration

Process Documentation

Bindery • Value Stream Map

• 5S activity – Sort, Set in Order, Shine, Standardize, Sustain

• Collect data on how long it takes to finish orders.

• Create process document

5S – Before and After

Printing

• Value Stream Map

• Standardize workflow

• Create process document

Printing Services Online (PSO)

• Value Stream Map • Survey to

customers • Created two new

portlets for order placing.

Key Points

• Educate staff on LEAN principals

• Conduct Value Stream Mapping to determine Current State.

• Collect data

• Remove barriers using LEAN tools

• Create a process document

• Remember to celebrate!

Questions?