Auburn Technical Assistance Center (ATAC)
Josh Malone on Lean Certificate Series
ATAC presented the Lean Certificate Series to train companies how to eliminate waste in their manufacturing plants. The series lasted from 8 a.m. to 4:30 p.m. Monday through Thursday. It concluded on Friday at noon.
Josh Malone the Senior Quality Engineer for Webster Industries, Inc. in Montgomery, Ala. attended the Lean Certificate Series. He plans on implementing his new knowledge about waste reduction in his office.
One of Malone’s favorite parts of the training was when he got to hear a professor from Auburn speak for 45 minutes about Lean Accounting.
“He described the plant I work for to a T. If he spoke again it would make me want to take a class with him,” Malone said.
A fun part for the students of the Lean Certificate Series training was the simulations. These focused on quick changeovers. They compared the current state to the future state.
One simulation took Malone’s group 28 minutes to complete because the directions were difficult to read. After changing the way the tools were positioned, how the die was assembled and after rewriting the instructions, the task took 30 seconds to complete instead of the original 28 minutes.
Webster Industries, Inc. will make more money if they can shorten the lead times for their customers. This is because what you make you can sell. As a result, the inventory decreases.
“Our changeover time can take one to four hours, but I’ve seen it done in 15 to 20 minutes which is a much quicker changeover,” Malone said.
One topic taught was the 5 Simple S’s. Shine, sort, standardize, set in place and sustain. The set in place objective explained how time is saved when things are organized and have a place. Employees can stay productive longer when they are not spending twenty minutes hunting for a tool.
“The Lean Certificate Series covers a lot of commonsense stuff, but by having it listed this way makes it practical,” Malone said. “We know what we should do, but we don’t have the tools to get there. This program shows how we can get the results we need.”
Another part included in the Lean Certificate Series was a plant tour of an Auburn manufacturing company. MasterBrand Cabinets Inc. currently uses Lean Manufacturing. Since they implemented the program, waste has dramatically declined. The Lean students were able to see firsthand a successful company operating with the changes in place.
Malone learned from the series on training which explained how to train and what to do when training. You are supposed to tell them, show them, give them the reason for what they are doing and the key points of their job and reasons for the key points. Lastly, reinforce the steps.
“They’re the ones making you the money so they should be involved,” Malone said.
Webster Industries, Inc. manufactures food bags and trash bags from recycled plastic. The company has been around for 52 years and processes have been done the same way. Since Webster Industries, Inc. has been successful, change could be tough because it may be viewed as unnecessary.
“Resistance to change is absolutely the hardest part of my job. Resistance at every level,” Malone said.
Mitch Emmons, Dave Devore and Hank Czarnecki had trained Malone and 19 of his co-workers a few months ago. The changes made should save Webster Industries, Inc. $100,000 each year.
“I came because I know what needs to be done I just needed the tools to make it happen,” Malone said. “I can take what I learned from this class back with me and show how it’s worked for other companies.”
Josh Malone the Senior Quality Engineer for Webster Industries, Inc. in Montgomery, Ala. attended the Lean Certificate Series. He plans on implementing his new knowledge about waste reduction in his office.
One of Malone’s favorite parts of the training was when he got to hear a professor from Auburn speak for 45 minutes about Lean Accounting.
“He described the plant I work for to a T. If he spoke again it would make me want to take a class with him,” Malone said.
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A fun part for the students of the Lean Certificate Series training was the simulations. These focused on quick changeovers. They compared the current state to the future state.
One simulation took Malone’s group 28 minutes to complete because the directions were difficult to read. After changing the way the tools were positioned, how the die was assembled and after rewriting the instructions, the task took 30 seconds to complete instead of the original 28 minutes.
Webster Industries, Inc. will make more money if they can shorten the lead times for their customers. This is because what you make you can sell. As a result, the inventory decreases.
“Our changeover time can take one to four hours, but I’ve seen it done in 15 to 20 minutes which is a much quicker changeover,” Malone said.
One topic taught was the 5 Simple S’s. Shine, sort, standardize, set in place and sustain. The set in place objective explained how time is saved when things are organized and have a place. Employees can stay productive longer when they are not spending twenty minutes hunting for a tool.
“The Lean Certificate Series covers a lot of commonsense stuff, but by having it listed this way makes it practical,” Malone said. “We know what we should do, but we don’t have the tools to get there. This program shows how we can get the results we need.”
Another part included in the Lean Certificate Series was a plant tour of an Auburn manufacturing company. MasterBrand Cabinets Inc. currently uses Lean Manufacturing. Since they implemented the program, waste has dramatically declined. The Lean students were able to see firsthand a successful company operating with the changes in place.
Malone learned from the series on training which explained how to train and what to do when training. You are supposed to tell them, show them, give them the reason for what they are doing and the key points of their job and reasons for the key points. Lastly, reinforce the steps.
“They’re the ones making you the money so they should be involved,” Malone said.
Webster Industries, Inc. manufactures food bags and trash bags from recycled plastic. The company has been around for 52 years and processes have been done the same way. Since Webster Industries, Inc. has been successful, change could be tough because it may be viewed as unnecessary.
“Resistance to change is absolutely the hardest part of my job. Resistance at every level,” Malone said.
Mitch Emmons, Dave Devore and Hank Czarnecki had trained Malone and 19 of his co-workers a few months ago. The changes made should save Webster Industries, Inc. $100,000 each year.
“I came because I know what needs to be done I just needed the tools to make it happen,” Malone said. “I can take what I learned from this class back with me and show how it’s worked for other companies.”
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Tags: ATAC, Lean Certificate Series, Lean Manufacturing, Alabama, Enterprise, Josh Malone, Lean, Training, Webster Industries, Inc.
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