Tony Ferraro

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  • in reply to: 5S – Setting in Order #78
    Tony Ferraro
    Moderator

    We implemented 5S a few times within our manufacturing warehouse and had a lot of success with it. However, we also found that the most difficult step to 5S is, Sustain. It’s essential to have a calendar in place to make sure that your 5S project is being sustained and continuously implemented. Employees like to fall back to their old habits and unfortunately, they also like to take shortcuts. Just because you implemented 5S doesn’t mean it’s over. It’s essential that someone takes control of the project even after the project is complete. This is all based on my experience.

    in reply to: How does Kaizen reduce waste? #76
    Tony Ferraro
    Moderator

    Kaizen has helped us better control our inventory and workflow processes. We realize we had no control over our production schedule and jobs were getting pushed to the floor when the order due date was 6-8 weeks out. This caused over-production issues and defects. The orders that were due, were getting pushed out with very minimal quality control. We ended up implementing an MRP system which helped us control our manufacturing jobs and manufacturing schedule. The employees were able to spend the time needed to get quality parts out the door instead of rushing through each job. Jobs were being released to the floor within the appropriate time based on work centers and takt time.

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