BY DENNIS SOWARDS , Quality Authority

Waste is everywhere but isn't inevitable, part 2

THE SEVEN TYPES of waste, which we identified last month (pg. 50), are:

Defects This is a product or service that contains errors, requires rework or does not function as designed.
Over-production of goods We create waste when we produce more than the customer needs or is needed at that time.
Transportation This is the waste of moving materials or goods.
Waiting When people, equipment or product wait for other processes or workers to finish an upstream activity, it is waste.
Over-processing This waste happens when there are unnecessary or extra steps in the process or if there are any steps that do not create value.
Motion Employees moving around do not add value.
Inventory Material or parts not currently being used by the customer is waste. In construction, this includes uncut sheet metal and pipe, work in process and finished fabrications.
Waste is everywhere. This is not a statement of blame, just fact. Enlightened managers see waste reduction as a competitive advantage. The rest see it as inevitable and unpreventable! Start driving waste out. Declare war on waste. Be a waste buster. There are many simple techniques that can help the construction industry attack waste. Here are some of the basic tools:

The 5S's came from Toyota and are used to organize and visually control the workplace to eliminate waste. The 5S's are Sorting, Simplifying, Sweeping, Standardizing and Self-Discipline.

SMACNA 2006 Partnership Conference

Download this PDF and see page 14.

Lean & 5S's in Construction

Newsletter #19 February 2007

Attack the Waste of Motion

MOTION: Employees moving around do not add value and is waste. These ‘treasure hunts’ happen when we store material away from the job or when workers must go looking for tools, material or information. Treasure hunts happen in the office, when we are looking for files, reports, reference books, current drawings, contracts or vendor catalogues. Poor planning and organization often cause this waste. It happens because we don’t have a designated place for everything. A good way to see this waste is to go to Gemba (where the work is being done) and watch.

These treasure hunts are easy to see, but hard to recognize! What I mean is that treasure hunts in construction are so common that we usually accept them as the way it is. We never question why! I was in a shop the other day and observed a man walk all the way from one end to the other, pick up a paper and walk back. A minute later he walked all the way again to pick up a pair of gloves. What waste, and he and the shop manager were oblivious to it. Watch workers in the field and you will see many treasure hunts going on all day. For each treasure hunt ask why – why do we have to go to this place or that location to get what is needed. Ask “why” five times to get at the root cause. Watching and asking why can lead to improvements by reducing motion. The 5S’s are a great tool for reducing waste.

Lean Works in Construction - Iselin, NJ
March 28, 2007
Sheet Metal Contractors Association of Northern New Jersey
Contact Donna Valentine at (973) 890-0890 smacna-northnj.org

High-Performing Contractor - NEWSLETTER

February 2007

This e-newsletter is dedicated to supporting SMACNA High-Performing Contractors and all contractors working to become one. Written by Dennis Sowards

**************** Leadership
Carlos Cardoso, president and CEO of Kennametal Inc., a manufacturer of metal cutting tools. He believes that every successful company shares the same three traits:

1. A clear vision and strategy that everyone in the company understands
   
2. The right processes in place to drive that vision to results
   
3. The right people to implement those processes

In short, while your customers are demanding that you build your products better, faster and cheaper, the key to doing that profitably -- which is the main point of being in business -- is to remain as competitive and productive as possible. In that spirit, then, hiring the best people, not just the most people, has become the new standard operating procedure for many U.S. companies.”

He also stresses that throwing money at technology is no panacea, especially if you don't recognize exactly what the problem is. "Whenever you're in doubt about what to do, just ask your customers. Whatever they tell you, that's the right answer,"

March 6, 2007 – Gaining Customer Loyalty by Design
Philadelphia, PA
Sheet Metal Contractors Association of Philadelphia and Vicinity
Contact Darlene at 610-828-4055, Ext. 207 dvalentine@smca.org

Lean & 5S' in Construction - Newsletter #18 - January 2007

***************** Attack Waste of Over Processing
OVER-PROCESSING: This waste happens when there are unnecessary or extra steps in the process or if steps that do not create value. The more steps in any process, the more chances for mistakes in processing. In construction this waste includes over-engineering, having to have someone’s’ signature on a requisition, multiple handling of timesheets, duplicate entries on forms or data-entry fields, and getting double and triple estimates from suppliers. Over-processing is caused by a lack of standard methods or processes, by poor communication and/or poor planning. Even when a standard process exists, this waste often occurs as the process slowly changes over time and it is not updated. A good way to detect this waste is to do a value stream, or even basic processes mapping, and look at all non-value added steps. Are these steps even necessary?