Introduction to Lean Factory Flow

Find the first half of my first chat with Hamish via my membership site here (unlocked for free access):
www.buymeacoffee.com/Freebird...
In this second half Hamish gives a detailed overview of the principles of ‘Lean Factory Flow’ that he uses to help joinery businesses become more efficient, and which I and my business Freebird Interiors benefitted from during our period of coaching with Bruce Poling at The Joinery Coach where Hamish was working at that time. Hamish is now offering his own independent coaching services specialising in this area of workshop efficiency, trading as Joinery Business Assist:
joinery-business-assist.odoo....
Get in touch with him if you’re looking for further support in this area.
**please note that this video originally went out on my membership site and the subsequent question and answer session mentioned in the video has been completed and can be found within the Pro Tier of the membership site: www.buymeacoffee.com/Freebird... **
Introduction to Lean Manufacture
1:08 -
‘5S’ - a way to get started with principles of Lean Flow for your joinery workshop, consisting of 5 principles beginning with S which should be tackled in order:
1:08 - Sort (get rid of unneeded things etc)
2:36 - Set (a place for everything and everything in it’s place
4:10 - Shine (keeping the place clean and tidy)
4:50 - Standardise (standard processes) and
6:22 - Sustain
6:45 - the importance of a shift in mindset and motivation (starting with the business owner) to ensure better habits take root.
10:48 - Communication, including the use of a large whiteboard, vs screens and software solutions.
12:54 - the power of making information visible to the right people
16:39 - detailed process map
18:43 - the difficulty of stepping up from a one - person business to a growing business which needs more systems for effective communication between team members.
20:15 - the importance of having standard process - the burden of communication can be reduced when standard methods are used.
20:52 - understanding true waste
21:36 - example of using open carts for storing and transporting plastic feet, bringing various benefits to workflow.
22:58 - example of a simple wheeled platform which massively reduced wasted motion, physical strain on staff, time and damage risk.
26:00 - example of using better organised hardware carts to eliminate various forms of waste
28:07 - the benefits of putting things on wheels
28:54 - examples of standard documents
Gemba docs link: gembadocs.com/
31:10 - training video linked to QR codes for training staff - pros and cons of videos vs a series of images and text
32:16 - the importance of scheduling your work. Principle of ‘pull scheduling’ (working back from the end process). Also sequencing - choosing the best order or manufacture
33:00 - using tall custom made wheeled carts to increase efficiency of drawer box manufacture
34:12 - it’s all about creating flow
34:48 - ‘game changer’ of storing and transporting flat parts on edge instead of in flat piles.
35:15 - visual management. And matrix board for prioritising tasks via impact and effort
37:28 - visual inventory management. Simple reordering system using boxes with 2 compartments. And Kanban card example
39:04 - the benefits of getting rid of doors on storage cabinets!
39:58 - checklists (a visual error proofing method).
40:09 - systems for recording errors (to help you prioritise where improvements are needed)
41:58 - productive maintenance.
43:02 - difference between reactive maintenance, preventative maintenance, and productive maintenance. Productive maintenance uses planned maintenance of machines as an opportunity also to upskill the operator and help them keep the machine in good working order day by day.
45:36 - CNC lubrication
46:33 - Innovation. Example of installing a ‘train track’ roller line in a large cabinet factory.
48:59 - more information on Hamish’s coaching services - what type of joinery business owner would be his target customer?
51:32 - Hamish can help with profitability via improved efficiency and scheduling. He also covers leadership and change management.
53:42 - answering questions about the effectiveness of coaching via Zoom not in person. Hamish is in Australia. He has had success coaching remotely but also acknowledges the benefit of meeting face to face and plans to integrate visits to the UK to meet his clients.

[@hurtinbombs]

Brilliant video ,
Thanks for sharing 👍

[@Alastair_Freebird]

Thanks for commenting, glad you liked it!

[@GreenEggs91]

KANBAN, Lean, gembadocs, servicem8 so much value in this video so thank you for posting!
As a joiner/cabinet maker who would like to go out on their own in the future all this info and experience is great to have out there!

[@Alastair_Freebird]

Thanks for commenting, I agree there was a lot of value in this video and I'm glad to hear it's appreciated.

[@adriandotsmall]

👍

[@samrix5793]

Awesome!

[@Alastair_Freebird]

👋🏻 hi Sam!

[@phuongnguyen7227]

I do not see any visible flows here. Can you make another video to show the flow is running please

[@Alastair_Freebird]

It is partially described in a diagram to the end of the preceding video, which is linked to in the description notes. Also this video shows the setting up of our workshop based on these principles: ua-cam.com/video/_UPuOOnn0hU/v-deo.html

[@Alastair_Freebird]

Just coming back to this video and saw these comments, and you can see an example of workshop flow in this brand new video (not strictly public on UA-cam at time of writing) from 12:50: ua-cam.com/video/w3DSV5aBF0Y/v-deo.htmlsi=UsEM9yGCRp5Zz1JL&t=770