Making your Portable Restroom business Lean and mean – How to boost productivity
and increase your bottom line
AGENDA
• What is Lean?
• How can it transform your business?
• How do you get started?
• Common pitfalls and mistakes
• Questions & comments
WHAT IS LEAN?
The research team found, upon studying Toyota and comparing them to the “Big 3” American auto manufacturers, that Toyota was able to produce MORE with LESS:
MORE:•Quality•Value•Innovation•Customer satisfaction
LESS:•Floor space•Inventory•People•Equipment•Defects•Accidents
The term "lean" was coined to describe Toyota's business during the late 1980s by a research team headed by Jim Womack, Ph.D., at MIT's International Motor Vehicle Program.
LEAN IS NOT…
• About laying people off
• A Japanese thing
• Only for manufacturing
• Only for large companies
• A “program”
• Only a set of tools
CORE CONCEPTS OF LEAN PRODUCTION
1. WORK = VALUE ADD + WASTE
Activities which meet the following criteria:• Customers are willing to
pay for it• Changes the fit, form, or
function of a product• Is done correctly the
first time
Activities which meet the following criteria:• Customers are willing to
pay for it• Changes the fit, form, or
function of a product• Is done correctly the
first time
Everything else!
• Increases cost • Lowers quality
Everything else!
• Increases cost • Lowers quality
2. RESPECT FOR PEOPLE• Engage the entire organization to eliminate waste
Seven types of Waste
Excess of Production
Inventory Transport
WaitingMotion
Unnecessary Process
Defects
THREE COMPONENTS OF A SUCCESSFUL LEAN TRANSFORMATION
• Culture• Operating system• Performance management system
THERE ARE MANY LEAN “TOOLS” TO HELP IDENTIFY AND REMOVE WASTE
• 5S – Workplace Organization
• Single Piece Flow / Cellular Manufacturing
• Visual Management
• Total Productive Maintenance
• SMED – Quick changeover from one product to another
• Kanban / Pull Systems
• Kaizen
5S IS A SYSTEM FOR WORKPLACE ORGANIZATION
Only the equipment, tools and material required for production is kept in the workplace
“A place for everything, and everything it its place”
Clean the entire workplace and all equipment
Use standard procedures and checklists to maintain a clean and orderly work area
Establish a system to monitor 5S to ensure that it is maintained
Sort
Straighten
Scrub
Standardize
Sustain
RESTROOM ASSEMBLY KAIZEN
Before:• Assemble 28 units at a time• 8 operators• ~60 minutes/unit assembly time
After:• 3 teams of 3 operators assemble one
unit at a time• 3 - 9 operators, depending on demand• ~45 minutes/unit assembly time (25%
productivity improvement)