Lean Manufacturing - Kaizen Methodology - Lean FastCap Style
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- Опубліковано 16 чер 2024
- (Get More LEAN at) paulakers.net/
#leanstartups #fastcap #fastcapproducts #2secondlean #banishsloppiness
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Paul Akers is the founder and president of FastCap, based in Ferndale, WA. FastCap is an international product development company founded in 1997 with over 2000 distributors worldwide. A prolific inventor, Paul holds many US and international patents. FastCap launches 30+ innovative products per year and has won Business of the Year multiple times. Paul and his wife, Leanne, have built FastCap from their garage into a multi-million dollar company. At its core, FastCap is a lean manufacturing company, determined to improve everything every day continuously. Our products reflect the idea that everything can be improved and the best ideas come from the shop floor.
For more information on FastCap, visit our website www.fastcap.com/
For Spanish videos, visit our FastCap Spanish UA-cam Channel. / @fastcapespanol
Paul Akers is an entrepreneur, business owner, author, speaker, & Lean maniac. He has written six books on Lean (2 Second Lean, Lean Health, Lean Travel, Lean Life, Banish Sloppiness, & Impact), and he travels the world to educate & speak about 2 Second Lean, Lean principles, & Lean manufacturing. Paul has a podcast called The American Innovator, where he shares his Lean travel adventures. For more information on Paul Akers and Lean, visit his website. paulakers.net/
To receive news regarding FastCap, New Products, & 2 Second Lean, go to this link: bit.ly/FastCap-Subscribe - Навчання та стиль
Thanks Brian. One of our most popular videos! Paul
What I loved about this is how open they are to give their own suggestions in front of their Big Boss. Just WOW! 😱
Great video. I continue to be amazed at how many sad, angry, souls, take the time to criticize things like this. Many people actually get excited (a positive emotion) by making things better. The people in these videos aren't paid actors, they just work at a place where their boss is crazy excited (in a positive supportive way) about making things better for everyone. Keep up the great work FastCap and keep spreading the word!
I'm a student at CAIS and in one of our classes we use the 2 Second Lean book and this video, and now the little voice in my head is slowly becoming Paul Akers. I can't even eat a hot pocket without thinking how wasteful it can be.
i keep seen this videos over and over through the years, going back to basics is a great refresher
This video explains Lean Six Sigma concepts better and more effectively than week long courses I have been forced to endure! Kudos!
Love hearing this! I think you might also like my book called 2 Second Lean available online for free. paulakers.net/2sl
I hope your class talked about the dabbawalas (tiffin carriers) of Mumbai, without any education how these guys have mastered the art of six sigma.
They have been granted ISO9000 1 error in 16 million transactions.
Point is sometimes you dont need the books but practical experience teaches u better and most effective ways to work.
www.themarkofaleader.com/the-dabbawala-six-sigma-sharing/
Perfect video thanks for information. Shows the power of sponsor and team effort
Great job FastCap. We live for this stuff, it's inspiring.
You, sir, are a great leader!
That's really nice example. It shows whole Kaizen philosophy. Good one!
what a wonderful example made, awesome you FastCap team.
Effective and simple to understand. thanks for video.
Thanks for sharing this video. Very good demonstration of Kaizen at work
I realize this is an old video, however you can probably save a few more seconds by cutting the bottom of the box and lifting it off, leaving all the cans standing upright. Also, depending on how the glue bottles are packed, they should also be standing up. Support the inserts on edge as well. Put your sleeve on the cone. Slide an insert out of the support, swiping it across the can as you slide the can over. Pull a glue bottle out next to the can, place the cone. Slide down and heat shrink. As an earlier comment suggests, add a banker's sponge for applying the sleeve to the cone as well as getting just one insert at a time.
Many, many thanks guys! It is the verry first I waching something about KAIZEN and is great. I already have an ideea and Monday it is ON! You are great!
Great ideas for the warehouse! You're doing a great service to others.
I really appreciate this video! After I watched it, I shared it with my Team before we do our next Kaizen because it clearly showed what Kaizen is and how its done. By driving the right culture to people and stimulating ideas this Team of 3 (+1) was able to come up with a great solution. Thanks!
I am a Cost Accounting professor. I've now shown this video to two different classes to introduce them to the Kaizen concept. This video is most excellent for my classroom purposes. Meagan is a great example of what I want my students to be when we create our own assembly procedures in the classroom.
Thanks Stephen. Love hearing this. This continues to be one of our most popular videos.
If you put a vertical, narrow mouth on the heat gun you would halve the time on the shrink wrap.
love the attitude behind this company and the staff!!! If you're ever wanting to open up in Australia please call me!!!!!
The best example of Lean Manufacturing I had ever seen, simple to show the concept!!
congratulation!!
Gerardo Thank you so much I appreciate it!
My favorite kind of process improvement!!! Paul
Thank you Paul.
thanks Paul & team. We will use this over the course of a week, as we do "2 Second Lean Book Club". Also, reduces that struggle too!
Great process raised by people!!
Congratulations
Great work and philosophy to not be afraid to try different techniques first! You lot are awesome
Thanks Onkarr.
Loved this!
Thanks. You made my day! Paul
you guys are awesome..thank you for this video. hope to see more Kaizen videos
Thanks for sharing guys! Very useful got me all psyched up.
+Dimitri Flores super!
That is great to hear. Thanks for sharing. Paul
This is awesome!!
nice work, and the best part is the willingness to share the ideas....thanks
Randy: We love sharing our idea. And love it when others share their ides. Sign up for our eBlasts to receive more! Paul
Great work guys!
Amazing video guys... Got Kaizen...
Thanks George. It's one of our most popular videos! Paul
Great example of Kaizen (Lean Manufacturing) !
@FastCap You could stand the tins up so the operative doesn't have to turn the tin vertical each time. The standard tin and glue could be a photo-standard instead, this means all stock will be used and you don't have to use actual stock for demo / specification purposes. The operative could also use rubber finger tips so they can pick up the sleeves easier. well done, good clip of lean continuous improvement.
This video is great. By the time I was done watching it I didn't realize 23 minutes and 21 seconds had passed. That's 1,401 seconds which equates to packaging about 100 of FastCap's 2p-10 Activators with your new lean method. Before you guys made these genius improvements, it would have only been enough time to package about 31 of product. We're talking about a difference of 60-70 products in barely over 23 minutes. That's amazing! Think about how efficiency like that applied to everything makes work so much more enjoyable and allows for more employee breaks (which are very important), and in the end, a more profitable company and happier, better paid staff who are happy to do their jobs. Thanks to all of you for that Kaizen demo.
Very educational. Really liking your videos.
Thanks Joey!
Teamwork and collective intelligence......incredible
Great video thanks for posting.
Mahmood Mili Thanks!
wow that was great!
Thanks, Omer!
Wonderful and amazing
Very good and useful
Megan has been doing every day since 2011 and has now made over 4.5 million. Great!
Thanks for sharing ! God bless you guys
Thanks! Paul
Wonderful video!
CheffingGood Thanks!
Brilliant!
The most impressive explanation of kaizen, btw still more to go, maybe grabbing glue and prescription at the same time near activator ( with asymmetric cone captures all at first sight, I believe this process can be done below 9 seconds :)
Wow what a great company. Awesome products and enthusiastic employees. You all have a great work culture over there. Thanks for sharing this, Aloha!
Thanks Nalu. You made my day!!! Aloha, Paul
Awesome!!!!
Just watched some your videos at Nissan training class awesome
Thanks, Arthur!
when adding these changes to a production line, we normally run 3 at a time and take the middle time. this way you capture end to end process time.
oh man.thats amazing,awesome.i love this.this is awesome.oh man.so cool.so awesome im so excited.awesome.
Paul - A really great video and thanks much for posting it. I've used it as a great example of Kaizen thinking at work.
George Friesen
Business Practice Leader - Lean Transformations
St. Louis Community College
@FastCap Why not save the operation by putting in the Insert by having it inbeded in the Can like a Peel off then you will remove the handling of the insert and save time ?
Qué pasote de vídeo. Muchas gracias por documentarlo y difundirlo.
Such a great and inspiring work! :D
+Daniel Sánchez You're welcome Daniel!
As a Process Engineer, I enjoyed this. Thanks. Always wanted to try your Glubot. I'm getting tired of clogged Titebond bottles.
Thanks. Let me know what you think.
Awesome guys
Hey Paul - if you ever open a factory in the UK, I need to work for you! Seriously though, thank you for opening my eyes as to how I can make my department work leaner, recognise waste and how best to empower my team. Our lean journey starts now!
You welcome, Lee. Keep me posted on your Lean journey. Send me some before/after videos.
Great training video for any company. A key point for me is Gram (sp) came in with an idea, that didn't make it in the final update. However, the concept was great, and helped move the group in the right direction. It shows the trust and respect for others with in the FastCap environment. I'm a new fan of FastCap, book on order.
David
+David Bogdan Hi David. Thanks so much for your comment! Very insightful!
thanks a lot
Great Video! This is really the meaning of continuous improvement. I'd make however one suggestion that everybody seemed to overlooked, the working table should be a little shorter so her wrists and elbows would be on a 0° working angle, safety first! then ergonomics. Greetings from México.
The managers enthusiasm does tend to take over solutions, instead of leading the team into making the solutions. But great example.
This is an awesome video. Thanks for posting. I wonder if you could not shed more time off your assembly if you placed the new units plastic piece on the funnel while the previous unit is heating. Almost like a SMED activity.
Pete Becker Pete, thanks for your feedback. It is amazing how much feedback we get on this video. It really seems to get the juices flowing for folks. This is an old video. The process it so different now. We have talked about doing an update video, but we haven't yet. We make improvements every day, so this process has changed tremendously!!!
I have this mentality and it is so amazing! I love working for the Air Force but there is so much paperwork to jump through to change something, even small. WHEN your company opens in Ohio I would love to be apart of the team. Having instant and critical feedback is valuable.
+discguyjoe To quote chapter 20 in my book "'My boss doesn’t get it and won’t support what I’m trying to do.' My reply is always the same; 'focus on yourself, develop your own area of influence and be relentless about continuous improvement in your life. If you adopt this approach, in short order you will not only rise up and be promoted, but you will eventually be the leader of your organization or another thoughtful organization that understands the power of true Lean leadership.'" It doesn't exactly apply to your paperwork comment, but I think you get my point. ua-cam.com/video/DhRjlIkj2Nw/v-deo.html
if the heat from the dryer gets the activator directly, is it safe?
sometimes it cures. or it has to be refrigerated, o kept at less temp.
Muy interesante y demuestra de forma practica la cultura kaizen en acción, una pregunta las posición de las latas la llegaron a cambiar en el transcurso del trabajo porque cambiar la posición para que en vez de cogerlas de la tapa la puedan coger de la base eso ahorra tiempo en girar la lata.
+Luis Enrique Villarreal Rojas
Gracias. Este proceso ha cambiado mucho desde el vídeo , pero es interesante para obtener retroalimentación de todos.
EXCELLENT IDEA
Thanks Siti!
Continual improvement 👍
Excellent, excellent video! I got sucked in and happily watched the whole thing. Amazing results. I have a huge respect for you and your company. I bought a bunch of Kaizen foam a few months ago and love it. I just wanted to say that I really appreciate these videos and your willingness to share methodologies so that small businesses like mine can thrive. I've already implemented a bunch of small things that I've learned from you and I hope to never stop improving. I make custom pocket knives with my brother and there are tons of little processes involved, so now we're actively looking at each one by itself to reduce time and increase quality. We used to live in Lynden too! Now we're in Toronto, but it's cool to know you guys are located near our home town. Cheers! John.
JohnGrimsmo Hey John: Great job on continuously improving. Send me your videos when you make them and show us how are you saving time and making work more enjoyable and rewarding! Paul@fastcap.com
FastCap You've got it Paul, I'll definitely be doing a video on the Kaizen foam. I'm actually staring at my desk drawers right now getting ready to install foam. I'm about 1/4 of the way through 2 Second Lean, you're the man! Thank you!
JohnGrimsmo Thanks John! Looking forward to what you come up with! Paul
Fun fact: legend says they make it now for 5 seconds, thanks to continious improvement they make.
where did you find it ?
And she went so fast, Megan started a fire because of all the friction.
With the time saved she was able to add a step of grabbing a streamlined fire extinguisher each time to douse the flames.
Really like her voice
Brilliant.
Thanks Steve!
Great Video... You are right to note that sometimes a view from outside the spectrum of operation can see something a little different. An example would be to raise the heat gun about three inches so she doesn't have to tilt the product to seal the top of the package. And yes is a fox with a great attitude.
Fred
Fred Skill Thanks Fred. Great idea!
mount a couple of those guns to the same surface, leave them on, get rid of the foot pedal and leave the table always rotating with a low speed servo and a pulley drive system, have a swiping arm attached to a stepper motor push the package to the side after every full rotation of the turn table and allow the operator to pack the sleeve while the previously packed package is rotating in heat shrinker. Bam, you've automated the heat shrinking process, bringing it back to a one person job, cutting your time in half whether she's faster or not.
Thanks for your input. Hard to believe how much insight we get from people watching this 2011 video!!!
Awesome!!!!!!
+Mario Del Campo Thanks Mario!
This was truly fun and explains kaizen so well! Especially when the new cone is introduced with popsicle sticks that don't work. Always listen to somebody that wants to contribute to kaizen. Ideas might seem crazy at first but they might improve the process.
I do have a suggestion: the girl is right-handed, but she has to cross hands when grabbing the little glue out of the box (she goes left). If she had the glues on her right side she wouldn't need to reach.
Mike Dusik Thanks Mike. Great idea!
I find this observation quite captivating. One possible improvement could be for her to consider using both hands to open the plastic, as it would ensure a smoother insertion into the cone.
I noticed this station in the background of a recent video. Could you show us what it has evolved to over the last 10 years?
@shoestringlean7163 We will ask our production crew to work on a video. Thanks for the feedback.
If they lengthened the can cap, they could put the small items inside there, have more room for advertising/information on the product and be more prominent at the point of sale.
Awesome
nice!
awesome
Great Vid, I work in industrial safety and lean has been a powerfull tool to get people involved and exited about safety. Have you seen improvements in safety as well?
greeting from Chile
Definitely.
is this a parallel universe where everything is perfect? and people understand each other? wow, in the place I work we all hate each other but pretend we are a team, ahahaha
haha..the best team ever..
Megan is hot.
Отличная демонстрация непрерывных улучшений на рабочем месте.
Спасибо!
could they have reduced the size of zip lock to match the two parts in first place or used a plastic attachment to hold the parts together
great input!
right hand sleave, left hand can, right hand insert, left glue grab both on can with left hand, comb right hand and pull down, right hand put comb back on spot, left is moving can to flat or two heaters...12 sec
great
Although this is 6 years later, one of the things I noticed is there wasn't a demarcation line Andey could use to know she'd dropped the insert far enough down the cone. her sleeve height affected her timing.
good idea
The nozzle of the heat gun should be redesigned to blow hot air in a vertical oblong pattern so the item doesn't need to be turned to distribute the heat. The heat gun should also be turned on just as the small bottle is dropped in to the sleeve.
Thank you for the suggestions! We have done these and MANY other changes in the years since this video was made!
A good movie, which depicts the essence of Kaizen.
But I noticed something else.
Time CT measurement cycle.
By definition CT - cycle time (CT) is the time that elapses between successive pieces of the downstream. In this case, the packaging process.
In this case also a good place to catch the cycle time may be the inclusion of the pedal to the heat gun.
It is important to capture the total time required for the packaging process. (This is important for the later calculations, for example. The production capacity of the workstation per shift).
However, the very essence of Kaizen - the optimization was very well presented.
I wish I worked at Fastcap
I just showed this video to the team at my dental office. So much good material here. I'd like to know where the three young "stars" are now. Do they still work at FastCap?
Andrey has his own homebuilding business. Graham is the lean leader for a company in CA/AZ. Megan is a full-time mother, the hardest job of all.
Wonderful news on all counts. You taught them well.
So Is She Coming Up With Lean Diaper Changing Procedures Or W/E Bugs Mothers With New Borns?
I'm sure she's adapted Lean to being a mother. That would be fun to know about.
It's a bluff Interm of seconds, initially lady doing the work alone, later next person helped him, work force doubles output doubled. Putting cone above the container is an good idea for kiazen test of the things is show off.
What do you mean, the next person helped? Is it when they are trying stuff out and he is holding the heat gun? I don't get it?
VERY interesting video on process control. I didn't watch the whole video, but was wondering if you guys thought about the boredom factor? I worked for the USPS for a number of years as a technician, and I noticed tons of people doing very menial, mechanical tasks, and I could imagine how mentally tired they got after a while. I noticed that some operators mitigated this somewhat with music via iPod type devices. Another thing management would do is rotate staff to other tasks periodically. Some tasks were eventually automated.
We have a fully integrated Bose sound system in our entire facility. Our people are cross trained to do 40 to 50 different jobs and they're always moving from job to job! Paul
Adding an oval hole into the side of the cone would allow you to drop the glue bottle into the shrink wrap while the cone is still attached. This would reduce the mental fatigue of having to navigate the glue bottle through the loose shrink wrap sleeve and shave off maybe another 1-2 seconds (which would be a 5-10% improvement over the final process time!).
Also, you could automate the heat process: Put a motorized lazy-susan on a pressure pad sensor that automatically activates the table's rotation and a mounted heat gun which has been calibrated to heat and rotate at the optimal rate/duration. This way you've eliminated 50% of the manual process and likely reduced the sigma in your shrink wrapping. If Andrey's wrapping process time is faster than the heat time, than you'd need to install a buffer in the process as well (something like a discrete conveyor which is sequenced to the start/finish signals from the heating process).
Thanks for the feedback! This process has changed a ton since 2011. It's on our list to make an updated video!
@@steventhehistorian Thanks for the feedback!
Multiple plastic wraps should be loaded on the cone in such a way that the employee does not fumble. The plastics wraps should be supplied in some kind of magazine format so that they are dispensed one after another. Plastic wraps should not be supplied in a flat stuck type of format.
(Magazine for mat means something similar to how facial tissues are dispensed from the box.)