well that was kind of surprising. I liked learning about how you got started and how far you have come. Great inspiration for organization for business and life. Thanks
I totally relate to how corporations take lean the wrong way. Much money is spent coming up with meaningless metrics that now prevail over the simple and obvious stuff. The biggest hurdles are sometimes unbelievably simple and cheap to solve but it looks insignificant to your boss so you won't care to do it. As you said, one must care about people more than metrics to do lean the efficient way.
This video really gathers speed and content as it goes and absolutely worth watching. Thanks for very valuable content, your an asset to your country, watching from Australia.
Thanks for sharing Jay, somehow I wasn't subscribed but now I am. Came over from Grimsmo's post. What a great story I enjoyed hearing about your lean journey.
A ton of machinists came into this world learning CNC, not many people prefer the conventional machines but definitely need the experience to overcome many cnc related problems. Yes, CNC is much better at production. Yes, you can get some serious money. Yes, you can make some really intricate parts, but if you’ve never made a 5 axis part on a conventional machine with tricks you come up with or learned, going as far as making 3D printing. You won’t be able to use the basic fundamentals to be the best machinist you can.
Man when John Saunders posted his video about M Hub and I saw you there I was praying you posted a video too. Yes!! Thank you so much for sharing. I've watched the Paul Acres videos too but yours just seem to resonate better. Thanks again :) Stephen
So inspiring! Thanks for sharing your story and tips Jay. When I start my business, I will try to implement everything you mentioned from the get go. Now, I’m off to your website for some LEAN/FLOW learning! 😀
Hi Jay, Great video. I have just one question regarding an answer to one of the questions you were asked. You mentioned that you make bonus stock if there is no other orders for the lathe as the setup is so difficult. Is this not overproducing and would reducing the process of machine setup not be a better approach? Reminds me of the Paul Akers’ story when the two young Toyota guys told him he could change a mold in 5 mins instead of 45.
Good question! First of all, not every component we make is a candidate for bonus stock. Only lathe parts (because they don't tie up an operator) and only if there's nothing else scheduled for the machine. Most of our setups on our mills are very easy (literally 5 minutes or less), but the Doosan 220LSYC is a complicated and time consuming setup that takes about an hour because every movement of the machine needs to be carefully watched to avoid tool collisions due to the small enclosure, main and subspindle chucks and big, live tool turret.
It was started by Toyota and it only works with a people-centric focus. Corporate America has shifted it to the profit-centric focus you've probably seen.
The size of the company doesn't matter that much. It mainly depends if the company has a focus on decentralized decision making or not. Corporations are traditionally centralized, meaning all the important decisions have to move up the chain of command, this is an old and outdated method. Lean has a chapter regarding this. I guess the businesses you've visited skipped that part. Any company that can't delegate decision making to the sites where it matters are just creating unnecessary bottlenecks in the overall production.
How do you balance the costs of finished goods inventory and WIP against the efficiencies of one piece flow. The most efficient is you get an order and you build it and ship it. Do this one order at a time. Any WIP of FGI may be necessary but are still a waste. Are we shooting ourselves in the foot by buying big machines that make lots of parts that go on a shelf rather than getting good at making product to order?
Yes! Overproduction is the most severe waste. Just-in-time production is the goal, but realistically it takes a lot of investment in processes to achieve true 1 piece flow.
Thank you. I don't know there is a proper name for this technique for managing a workspace as I am practicing the almost the same but more on efficiency side, now I know more, thanks again for clarify, now I know what should I do.👍
"Lean is a snowball thing" Heck yeah. One of the biggest hurdles I've found in advocating for lean is that the first few major waste cutting initiatives don't pay off by themselves. Just like all waste types compound each other, cutting wastes pay off the most when the cuts multiply.
I've seen your videos and most of Paul Akers videos. I would really love to apply the 3S in my company, but it's hard to engage to my fellas with the improvements. Do you have any advice on how engage people. It's a tiny company but I can see waste everywhere and I would like to improve it. Thanks and congratulations for your success.
Start with the complainers. If they complain, it's because they care (they may never admit it though). The ones that are ok with being average are not the ones to lead the transformation.
what an amazing story.... the part that I am interested in is if it is even possible and in your case how do you think that you built your problem solving mentality because I that mentality is your biggest "it" factor Not just problem solving but you also add the kaizen mentality which is weird that I never heard you mention.
Hey Jay! I work in my Dads manufacturing shop and this video really helped me, we are trying to implement lean, i would love to know what walkie talkie app or system you were talking about along with the QR code video system, if you could provide for in-depth information on that or names of these apps, that would be super awesome!
Omg! I have been saying we need walkie-talkies at my shop! So much of this stuff actually would benefit my shop...it's just convincing the bosses of it.
@Pierson Workholding we r apparently looking into some pallette systems for the shop, though. I'm very excited about that. I already have an idea of how to use them.
Im buying first 2 months from reliable but expensive product, but the turn around is dumb lol so reliability vs profit vs over head is dumb, ill buy tons of 5 axis by the time i need to worry about worrying about training
It was made in Adobe Illustrator and any local print shop like Kinko's should be able to make a spiral bound notebook. I heard Amazon also prints 1 off books too.
Make the thing you want people to do the easiest solution. If you have to open a drawer to put a drill back 50 times a day, take the drills out of the drawer. Dont want people taking a brand new drill every time they need one? put the new drills in a big heavy drawer and put ONE drill in the handy close to the machine index. Lean will steer people to the fastest most efficent solutions, thats the entire point. You dont have to convince people to adopt it
I’m amazed at millionaires from back then and the grind applied to attain the achievement of being a millionaire. Now it’s a bit easier to become one but that’s probably because of inflation.
Ugh, I wish I worked in a lean shop. I have to hunt for things all the time. I hate this phrase, but it really triggers me 😩 Feels like you're running just to stand still I have to walk the entire length of the workshop (about 100m/330ft) to check parts on the CMM. Sometimes I get a part that specifies 100% in process inspection. That's 200m every 1/2hr or so.
What you described is "profit-centric" Lean. We practice "people-centric" Lean. If it takes my guy 2 hours for a setup, then the setup takes 2 hours. Our ongoing job is to make improvements to cut setup time by eliminating waste.
✅ Learn more about LEAN & sign-up for LEAN TIPS 👉 piersonworkholding.com/lean/
Thanks for posting this, Jay - and thanks for sharing some of your story (and struggles) with Pierson Workholding.
This is the maybe the first no-BS video I've seen on lean. Thank you! I'm going to dive into this.
Muchas gracias por compartir su notable experiencia
Thanks for posting this Jay. I'm glad you started making these vids cause the way you present them is right in line with the way my mind works.
well that was kind of surprising. I liked learning about how you got started and how far you have come. Great inspiration for organization for business and life. Thanks
Hey Jay what an amazing video you are over the top good!!!!!!!!
You rock man, great presentation and even better delivery. Great story telling.
So much great information for when I start my shop. Love your process!
I totally relate to how corporations take lean the wrong way. Much money is spent coming up with meaningless metrics that now prevail over the simple and obvious stuff. The biggest hurdles are sometimes unbelievably simple and cheap to solve but it looks insignificant to your boss so you won't care to do it. As you said, one must care about people more than metrics to do lean the efficient way.
This video really gathers speed and content as it goes and absolutely worth watching.
Thanks for very valuable content, your an asset to your country, watching from Australia.
Another super great video Buddy! I had no idea you are such a great speaker! Thanks for sharing your story Buddy!
Thanks for sharing Jay, somehow I wasn't subscribed but now I am. Came over from Grimsmo's post. What a great story I enjoyed hearing about your lean journey.
A ton of machinists came into this world learning CNC, not many people prefer the conventional machines but definitely need the experience to overcome many cnc related problems. Yes, CNC is much better at production. Yes, you can get some serious money. Yes, you can make some really intricate parts, but if you’ve never made a 5 axis part on a conventional machine with tricks you come up with or learned, going as far as making 3D printing. You won’t be able to use the basic fundamentals to be the best machinist you can.
qr codes and videos - man that is a good stuff, super
36:36 stuck in speed trap - yeah yeah exactly
nice talk for sure
I LOVE LEAN
Great information share! Enjoyed your communication style and leadership approach.
your testimony is awesome bud
Man when John Saunders posted his video about M Hub and I saw you there I was praying you posted a video too. Yes!! Thank you so much for sharing. I've watched the Paul Acres videos too but yours just seem to resonate better.
Thanks again :)
Stephen
Good to hear! We have more content coming of this nature.
Jay fantastic job so clear!!!!!
Thank you Paul! Honored to know you watched it.
You got a like for dumping the girl to go make parts lol.
14 dislikes was that one salty girl and her friends. Lololol. Never know what a dislike means. Usually useless. Can't please everyone.
Did Jay make the Mountain Speed FSR Long travel kits????! I had one back in the day and it was awesome!
So inspiring! Thanks for sharing your story and tips Jay.
When I start my business, I will try to implement everything you mentioned from the get go. Now, I’m off to your website for some LEAN/FLOW learning! 😀
Great story
Hi Jay,
Great video. I have just one question regarding an answer to one of the questions you were asked. You mentioned that you make bonus stock if there is no other orders for the lathe as the setup is so difficult. Is this not overproducing and would reducing the process of machine setup not be a better approach? Reminds me of the Paul Akers’ story when the two young Toyota guys told him he could change a mold in 5 mins instead of 45.
Good question! First of all, not every component we make is a candidate for bonus stock. Only lathe parts (because they don't tie up an operator) and only if there's nothing else scheduled for the machine. Most of our setups on our mills are very easy (literally 5 minutes or less), but the Doosan 220LSYC is a complicated and time consuming setup that takes about an hour because every movement of the machine needs to be carefully watched to avoid tool collisions due to the small enclosure, main and subspindle chucks and big, live tool turret.
Lean has never worked in a corporate environment I visited. Only in small empowered places
It was started by Toyota and it only works with a people-centric focus. Corporate America has shifted it to the profit-centric focus you've probably seen.
@@jaypierson5955 I am sure you are right and any company that is traded can't grasp that..
@@TheRetiredtech Not true! Google "Shingo Prize" and you'll see a list of public companies that get it.
The size of the company doesn't matter that much. It mainly depends if the company has a focus on decentralized decision making or not. Corporations are traditionally centralized, meaning all the important decisions have to move up the chain of command, this is an old and outdated method. Lean has a chapter regarding this. I guess the businesses you've visited skipped that part. Any company that can't delegate decision making to the sites where it matters are just creating unnecessary bottlenecks in the overall production.
@@mctigmctiggy1475
You just said meetings did not add value to the product. That's the opposite of lean. Ergo no, they did not try it.
How do you balance the costs of finished goods inventory and WIP against the efficiencies of one piece flow. The most efficient is you get an order and you build it and ship it. Do this one order at a time. Any WIP of FGI may be necessary but are still a waste. Are we shooting ourselves in the foot by buying big machines that make lots of parts that go on a shelf rather than getting good at making product to order?
Yes! Overproduction is the most severe waste. Just-in-time production is the goal, but realistically it takes a lot of investment in processes to achieve true 1 piece flow.
Thank you so much for posting this Jay. Very informative and inspiring!
Thank you. I don't know there is a proper name for this technique for managing a workspace as I am practicing the almost the same but more on efficiency side, now I know more, thanks again for clarify, now I know what should I do.👍
this is brilliant
"Lean is a snowball thing"
Heck yeah. One of the biggest hurdles I've found in advocating for lean is that the first few major waste cutting initiatives don't pay off by themselves. Just like all waste types compound each other, cutting wastes pay off the most when the cuts multiply.
What is the difference between bonus stock and over stock?
Bonus is something you over made and over stock is something you ordered of thats too much
I've seen your videos and most of Paul Akers videos. I would really love to apply the 3S in my company, but it's hard to engage to my fellas with the improvements. Do you have any advice on how engage people. It's a tiny company but I can see waste everywhere and I would like to improve it. Thanks and congratulations for your success.
Start with the complainers. If they complain, it's because they care (they may never admit it though). The ones that are ok with being average are not the ones to lead the transformation.
Awesome!
Nice video to watch, you inspired me!. I work for a machining shop called VIMA and it seems we have much to improve.
Greetings from Coahuila, México.
Thanks for the Video, Jay!
Hey Garth... glad you watched it!
thank you Jay, great content
what an amazing story.... the part that I am interested in is if it is even possible and in your case how do you think that you built your problem solving mentality because I that mentality is your biggest "it" factor
Not just problem solving but you also add the kaizen mentality which is weird that I never heard you mention.
Hey Jay! I work in my Dads manufacturing shop and this video really helped me, we are trying to implement lean, i would love to know what walkie talkie app or system you were talking about along with the QR code video system, if you could provide for in-depth information on that or names of these apps, that would be super awesome!
There are lots of choices. Search "QR code printer" on Amazon and "walkie talkie app" in your app store.
Omg! I have been saying we need walkie-talkies at my shop! So much of this stuff actually would benefit my shop...it's just convincing the bosses of it.
Leaders don't need titles to lead. Just tell your coworkers to install Voxer, Whatsapp or Signal. Don't let your boss hold you back.
@Pierson Workholding we aren't allowed our phones either or I would have suggested that.
@Pierson Workholding we r apparently looking into some pallette systems for the shop, though. I'm very excited about that. I already have an idea of how to use them.
What you are talking about is ISO EN DIN 9015:2015 :D Thanks for the video.
Thanks for sharing Jay!
Thanks Jody. More to come!
Im buying first 2 months from reliable but expensive product, but the turn around is dumb lol so reliability vs profit vs over head is dumb, ill buy tons of 5 axis by the time i need to worry about worrying about training
Great video! I found your podcast from about 10 years ago, they were really good. P.S. Love my mini pallet system!
Thank you. My old podcast... yeah, let's not bring that up. :)
Jay Pierson Just have to keep in mind the podcast quality standards have been raised quite a bit since then. The info was solid! 👍
How did you make your note book? Publisher. Excel or do you have a company print them this would be very useful
It was made in Adobe Illustrator and any local print shop like Kinko's should be able to make a spiral bound notebook. I heard Amazon also prints 1 off books too.
It's Toyota's 6S Lean Management System. Great thing.
Very interesting
Make the thing you want people to do the easiest solution.
If you have to open a drawer to put a drill back 50 times a day, take the drills out of the drawer.
Dont want people taking a brand new drill every time they need one? put the new drills in a big heavy drawer and put ONE drill in the handy close to the machine index.
Lean will steer people to the fastest most efficent solutions, thats the entire point. You dont have to convince people to adopt it
Amazing, wish I could have been there, next time for sure!!
only hjave one think for to say: woow
i like very much this video
I’m amazed at millionaires from back then and the grind applied to attain the achievement of being a millionaire. Now it’s a bit easier to become one but that’s probably because of inflation.
one - metalica
Ugh, I wish I worked in a lean shop. I have to hunt for things all the time. I hate this phrase, but it really triggers me 😩
Feels like you're running just to stand still
I have to walk the entire length of the workshop (about 100m/330ft) to check parts on the CMM. Sometimes I get a part that specifies 100% in process inspection. That's 200m every 1/2hr or so.
start with yourself - and others will become curious with time
It's all good on paper then they chop setup times an goodbye clean organized work areas
What you described is "profit-centric" Lean. We practice "people-centric" Lean. If it takes my guy 2 hours for a setup, then the setup takes 2 hours. Our ongoing job is to make improvements to cut setup time by eliminating waste.
Litterly al the things that are wrong in my shop its about this
John, your mic wasn't on, but I could make out what you were saying..