Gain the Competitive Edge

	Gain the Competitive Edge...
	Lean Manufacturing - St. Lucia Style

June, 2005 Recent Events: Paladin exhibited at RPCN's annual conference on May 11th. Stephen Phillips spoke at the International Resource Group on May 24th.		Lean Manufacturing or the "Toyota Production System" is based upon three principles: Voice of the Customer - providing product when the customer wants it Standard Work - a basis for continuous improvement Elimination of Waste - defined as anything that the customer does not pay for Refer to our website for suggested reading and web links on Lean Manufacturing. Traditional "batch" process manufacturing encourages the use of large equipment. Factory efficiency is measured by machine utilization. This tends to create long lead times and does nothing in terms of getting product to the customer as they need it. Over-production and large inventories are common. Parts spend a lot of time in transit and waiting to be processed. Quality defects when found require the screening of large batches of parts.
		We use a standard work instruction card with every operator. As much as possible the instruction cards are pictorial with clear examples of quality parameters. These can be changed quickly with each job.

			Work is performed by one-piece-flow cells - there are no batches. Each operator completes a step and passes the work to the next operator. This means that product is completed within minutes rather than in days or weeks as with traditional manufacturing. Each operator inspects the work of the previous operator and provides instant feedback if there is a quality defect. (Work instructions removed for picture)

		In cases where a batch type of process is required such as epoxy curing, the smallest batch possible is used. Methods are employed to reduce the wait time such as curing ovens. In all cases equipment is right-sized for the job. Use of large equipment that can do more parts than required is discouraged.

			This curing oven was built for this job and supports the correct rate of manufacture. Lean manufacturing calls this "takt time" and it matches the rate at which the customer uses the parts.

		The next curing stages also uses a oven and again the oven is made just for this job and is right-sized.

			Parts are inspected, tested and packaged right on the work cell.

Box 265 Fairport, NY 14450 585.330.5337 www.paladin-mfg.com	Learn more at Paladin's Website This email was sent by Paladin Manufacturing Corp. Visit our newsletter page to sign up or to unsubscribe. View our privacy policy.