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Problem Solving Using the Why Tree by xtremelean.us

 

* This presentation is on problem solving using the why tree and is designed to teach a standardized approach for your people at all levels of the organization. Good problem solving skills within your company will cause your business to thrive while making everyone's life easier in the process.

* While problem solving does not have to be difficult, there are many that like to make it sound that way.

* People are not born as natural problem solvers and you don't need a college degree to learn to be a good problem solver either.

* Good problem solving skills can be taught and that is what I am going to do. My goal is to teach you a simple standardized approach that can be used in your business or personal life. You can also use this training video to teach others at your business. When completed, you will fully understand and be ready to use the concepts taught here.

* When we become good at problem solving, we start eliminating the problems that cause our head to spin once and for all. Our life becomes much easier and we suddenly have more time and less frustration. You are probably watching this video because that is exactly the direction you want to go in your life.

* Let's first discuss what a problem is or is not.

* A problem is the difference between actual conditions and the desired conditions and you don't know how to solve it.

* Let's put this in simpler terms.

* Let's change desired condition with "Want" and change actual condition with "Have"

* So the difference between what we have and what we want is the problem.

* And it's only a problem if you don't already know what the solution is.

* Let me give you a simple illustration of what a problem is. Barney here wants a female companion, but he does not have one, and he doesn't know exactly what to do about it. That is Barneys problem. That seems pretty straightforward doesn't it?

* The biggest type of problem people face is when something suddenly goes wrong.

* Captain Jack here is flying 300 passengers across the continent when all of a sudden, the plane starts to go down.

* In this case, the pilot WANTS to have full control of the plane again.

* But what he has is a plane that is going down and he doesn't know what happened or what to do about it.

* Does the pilot have a problem? 100% affirmative.

* Everyone has problems in their life at one time or another, so we all have the responsibility and opportunity to solve problems many times in our lives. It is absolutely best when we solve a problem so it never ever returns again. When you solve problems this way, your life becomes easier.

* When it comes to problem solving, some people just start shooting from the hip. This can be a very costly, time consuming, and frustrating approach. Preferable to this would be to take some aim at our target. After all, if we take the time to aim carefully at our target we increase the chance of hitting the bulls eye.

* Let's use a hypothetical problem that everyone can relate to. You arrived to work late.

* By the way, always clearly define the problem in as few words as possible, while also making sure everyone can understand what the problem is.

* And the reason we arrived to work late is because our car would not start.

* Many people put a lot of emphasis on root cause analysis, which is finding out what exactly what caused the car not to start.

* This is a fish bone diagram which is another tool that can be used for determining the root cause of a problem.

* And while sometimes finding the root cause is important, finding the best solution that will prevent the problem from reoccurring is THE most important objective.

* In this case, let's say you were at the end of your ropes with this piece of junk anyway and had decided you were going to buy a new car.

* Do you really care what exactly caused your old car not to start? Not really.

* Will the new car be a proper solution to your problem and get you to work reliably for many years to come? Absolutely

* My point is, solutions are more important than causes and in my opinion, outweigh them greatly.

* All right, let's do a reality check. You have a crap car, you were late to work because it would not start, and you have no money to buy a new car.

* You now need to know what caused your car not to start so you will not be able to fix it.

* The Why Tree method is the focus of this presentation, but it relies on knowing the 5-Why root cause analysis method. The 5-Why method for determining root cause is one of the simplest methods to learn and to complete. You start with a clear problem statement, then ask why the problem happened and write the answer down. If that answer did not identify the root cause, continue asking why until it does.

* Let's go through an example.

* For example our problem is we woke up late.

* We would then ask "why did we wake up late?"

* The alarm did not go off.

* "why did the alarm not go off?"

* Because the time reset on the alarm clock?

* Why did the time reset on the alarm clock?

* Because the power went out.

* Why did the power go out?

* Because of the severe thunderstorms.

* Why were there severe thunderstorms?

* We don't know.

* Notice that solutions are out of our control when the power went out? We do not have control over the power or the weather. So the line of questioning should stop when we do not have any control over the cause.

* One of the problems with the 5-Why root cause analysis is it only allows for one line of questioning. Based on the answers you give, you can get off the trail to solutions very quickly.

* Let's back up and change the answer to "why did the time reset on the clock?" to:

* Because the clock lost power

* Then why did the clock lose power?

* Because the alarm clock did not have the backup battery installed.

* Why was the backup battery not installed?

* Because we did not have one at the time.

* Take notice that the answers you give will dramatically change the outcome. You must also ensure the answers are accurate or once again you will be on a wild goose chase.

* We now have a root cause that we have control over and an easy solution to the problem. Having a backup battery installed in the alarm clock allows it to continue working in the event of a power outage. This solution is very simple and effective with a very low cost. It is easy to implement and has no negative consequences.

* While you now have a good solution to this problem, let's not forget that batteries do not last forever. You will need to check the batteries in the alarm clock on a regular basis if your want to eliminate this particular problem forever.

* Even though this approach is called 5-Why, 5 is just a rule of thumb for the number of times to ask why. It could be more or less though depending on the problem. When you no longer know the answer to the question that is a good place to stop. Speculation will rarely serve you well.

* While the 5-Why root cause analysis is a good and simple tool, I find the Why Tree diagram is a much better tool for brainstorming multiple possible causes of the problem. Discovering multiple causes of the problem allows you to develop multiple potential solutions to the problem. You would use the same 5-why approach but the tree diagram allows you to list multiple potential causes to each why. There is no limit to the size or shape of your Why Tree. Let me share an example of using the Why Tree.

* Let's use a real life problem I experienced recently. We put in a new lawn at our house and it wasn't very long before I noticed the grass was dying is some areas. I was upset and wanted to know why and the solution to the problem.

* It did not take long to put two and two together. The dog peeing on the lawn was causing it to die. The reason I want to share this example with you is to show you there are almost always several solutions to any given problem.

* While you may have multiple solutions for any given problem, and even though all of the solutions may solve the problem, there are costs or consequences to consider. Your job in good problem solving is to come up with:

A: The simplest

B: Most effective solution

C: At the lowest cost

D: That is the easiest to implement

E: With no negative consequences.

 

* The description of my problem is very simple "my grass is dying in small sections". So the 1st question why is the grass dying? Because the dog is peeing on the grass, why is the dog peeing on the grass? Because he is not trained to go elsewhere.

* I must confess, when I first saw that the dog peeing on the grass was causing it to die, I jumped to my first solution and that was a well planned hunting accident where the dog had more to worry about than the bird.

* But that solution would end up in divorce court. Although this solution would be simple, 100% effective, relatively low cost, and easy to implement, the consequences of this solution would make it a very poor choice.

* Then I thought how can I train the dog to stay off the nice new lawn?

* Someone suggested setting up an electric fence and I thought that would be a perfect solution. So off to the pet store I went only to discover these fences aren't cheap. Although this solution would be very effective and there were no negative consequences I could foresee, the cost was high and not simple to install or implement. Still the best solution I have found up to this point.

* I realized I needed to dig deeper to find more causes and therefore more solutions so I asked myself again, "why is the grass dying?"

* Because of the dog pee. I don't have any control over the natural functions of the dog so there is no solution there.

* Why is the dog pee causing the grass to die?

* I had to do some research on the internet, but quickly found my answer. Because dog pee has high levels of Nitrogen.

* Why are there high levels of Nitrogen in the dog pee?

* I also found the answers on the internet that it could be related to their diet

* Or they are not drinking enough water.

* I investigated changing the diet for my dog and found that over the lifetime of the dog, you will probably spend more than the electric fence. I also found out there are health risks for the dog with this diet. I found this solution to be simple, but the effectiveness in my mind was questionable. The cost was again high and the negative consequences of the health of the dog were not exciting. Bordering again on the divorce court thing.

* The dog not drinking enough water was another cause looking for a solution.

* I also thought I could probably teach my dog to read before I could get her to drink more water. So while this solution may be effective at a low cost with no negative consequences, I did not feel this would be simple or easy to implement at all.

* We might not be able to get the dog to drink more water which would dilute the Nitrogen, but maybe we can dilute the Nitrogen another way. What if we adjusted the sprinklers to come on more frequently in the area the dog goes potty? Here is an extremely simple and easy to implement solution that should be totally effective with no cost or negative consequences. Guess what solution I chose to solve my problem?

* There is a simple way to cross check the solution you have chosen. Just read your Why Tree in reverse order and substitute the question why with the word because. Let's try this.

* We are going to adjust the sprinklers to come on more frequently because we need to dilute the high levels of Nitrogen because of the dog pee, because the dog pee is killing the grass. Make sure when you do the cross check that your solution makes sense all the way down the line.

* Root cause analysis is definitely a team effort. After all, two heads are better than one. Choose your team members wisely and keep the team size to a manageable group however.

* Don't worry about the repeatability of this problem solving process. In my mind, problem solving is a very creative process.

* If you give the same problem to three different teams, depending on the creativity of each team, you will most likely end up with three different solutions to the problem. This is absolutely normal. Just be creative and focus on the best solution to the problem you face and implement it.

* If this process does not give you a solution that is clearly correct, you may need to use a different problem solving tool.

* In the future, I will be posting videos on all of the problem solving tools including, Pareto charts, flow charts, fishbone diagrams, brainstorming tools, mind maps, failure mode and effects analysis, and TRIZ. So stay tuned.

 

This is the end of the presentation, but the beginning of your journey towards realizing the benefits of good problem solving at your own company. We have many years experience in the tools of Six Sigma with problem solving skills at the forefront. Let us know how we can help you.

If you need help in training or implementing problem solving, visit us at www.xtremelean.us

Using a Chemex is my personal favourite way to brew filtered coffee. The slower extraction time lends to a much sweeter and complex flavour in the cup. I find a more syrupy mouthfeel. It is very easy to use, so we put together this brewing guide to show you how you can use this in your cafe, home or work place.

 

Watch this short video that takes you through the steps to do this yourself.

Storyboard No.1 from the OFPP & UNEP/UNESCO GAFI "Orangutans and Palm Oil: Conflict Mitigation Training Video"

 

Find out more about the Orangutan Film Protection Project @

www.cockroach.org.uk

And watch some of our outreach work streaming online:

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* 5S is an integral part of Lean and Set-in-Order is the second stage of 5S. Set-in-Order is probably one of the most difficult steps in the 5S process, but there are also more tangible benefits from implementing Set-in-order.

* If you have not already done so, you might want to first watch our 5S Overview and Sort videos.

* In review, the 5 S's are Sort, Set-In-Order, Shine, Standardize, and Sustain in that order. We will now focus on Set-in-Order for the remainder of this presentation.

* Set-in-Order means arranging all of the items you have determined are necessary for production so they are easy to find, easy to use and easy to put away when finished. This includes determining the best locations for machines and equipment. Locations should be created for each item and clearly labeled. This reminds us of an old adage, "a place for everything, and everything in it's place".

* Before you even begin Set-in-Order ensure that the Sort phase is completely finished. After all, why would you want to spend time creating locations for items you don't even need?

* You already know a little bit about this phase of 5S, because we all practice Set-in-Order in areas that are important to us. For example:

A: When it's time to eat, do we have to search for silverware, or do we have it perfectly organized and ready right where we need it?

B: For you golf enthusiasts, the golf bag and cart are a perfect example of set-in-order. The clubs all have their own specific location, the cart holds the bag at just the right angle to allow the clubs to be easily retrieved and put away again. And there are special pockets for balls, tees, and every other accessory needed.

C: Fishermen are the same way. When it comes time to find that special lure or any other piece of fishing equipment they have got it going on.

D: Is hunting your sport? I'll bet you have a special cabinet at home where you carefully store all of your guns, ammunition, and other accessories where you can easily find them.

E: And...well, you get the picture. If it's important to us, we practice set-in-order.

 

* If we can make our workplace as important to us as our favorite sport or hobby, and practice set-in-order, we would enjoy our jobs much more than we do now.

* 5S is also referred to as a visual workplace. Set-in-Order is the method we use to create a visual workplace. We want everything to be organized so we can know the status of everything at a glance.

* In this example you can clearly see one tool is missing and by the red shape, you can tell even from a great distance away, it is the hammer that is missing.

* In this example you can see that all of the brake form tooling is well organized, labeled, and color coded. It is very easy to find the tools you need and put them back in the correct place afterwards.

* Our inventory needs to be organized so we can learn at a glance the status of it. The clear Plexiglass in this example allows us to review all inventory levels at once.

* Here is a great example of setting up your inventory so you know exactly when you need to replenish it.

* Another example of setting up a Kanban area where again at a glance you know the status.

* You also want to create a workplace where the flow of work is obvious to anyone.

* With visual instructions on how the work is to be performed

* Kanban boards are an excellent visual tool.

* Set-in-Order applies to safety equipment also. You want fire extinguishers to be visible so anyone can locate it in case of emergency.

* You also want to make first aid kits visible and easily accessible in case of an emergency.

* Let's look at some storage options to consider, for example:

A: Some items can only be stored on the floor such as large machines or other large items.

B: Some equipment can be made portable, which is ideal for flexible manufacturing

C: Racks and Shelving can increase your storage capacity in a small amount of floor space

D: And carts on wheels can be very helpful

E: Flow racks can be used for work in process

F: Storage bins are easy to identify and great organizers and space savers

G: Cabinets

H: Shadow Boards

I: And also tools that hang from the ceiling

 

* When it comes to implementing Set-In-Order, it's just like real estate. It's all about location, location, location. Let's talk about how to decide appropriate locations for items.

* First let's create a spaghetti diagram to determine where the operators have to travel to get the items they need for production. This is easily done by observing and tracking the operators as they go about their normal production.

* Here is an example of what a completed Spaghetti diagram looks like. Use this diagram to improve the layout of needed items by identifying and eliminating any excess motion. By locating parts, equipment, machinery, and tools in the best locations possible, we can minimize motion waste. Keep in mind that locating machines close together may give you the opportunity to have one person operate more than one machine as shown in this example. A proper layout improves flow and requires less people for production, which improves productivity dramatically.

* Locate items based on the frequency of their use. The more an item is used, the closer it should be to the actual point of use. This shadow board mounted on the outside of this CNC machine could not be better positioned. This Brake Form machine has all of the necessary tools for set-up stored close by for easy access. Here is an example of a machine that needs to be adjusted on a daily basis. In this case it would be wise to store this wrench as close to the actual point of use as possible, even if it means having to buy an extra wrench to do so. Do not store items in a manner that would cause unsafe conditions however.

* If items are used together they should be stored together. For example, this drill, drill chuck, and drill bits are all used together, so they should all be stored and organized in the same place. This helps eliminate searching waste.

* Be creative when implementing set-in-order. Set-in order is only limited by your imagination. This safety barrier for the Timesaver Deburring machine doubles as a storage location for the sanding belts that are needed for that same machine.

* If applicable, develop tools that retract to a home position so that you will always know where it is. Here is an example of a drill that when you let it go of it, it moves up and out of the way. Here is an example of a hose reel that takes care of storing that needed item.

* When it comes to the tools that you use, you are in complete control. Here are some different tool options to consider:

A: Develop tools that serve multiple functions. This means less tools to store and create locations for.

B: Think about using a substitute for the tool; the need for this wrench for example can be eliminated...

C: With a nut like one of these that can be turned by hand.

D: Also think about eliminating tools and speeding up the process significantly by substituting a different method. For instance, automatic clamping can be used instead of nuts and bolts saving a great deal of manual labor.

 

* Creating locations for items will limit how many items can be stored in the area and when done properly will give good visual control on inventory levels as shown in this example. This makes it impossible to store more items than are necessary in a given area.

* Outlining is used on floors to show the location of a particular item and also to limit the amount of inventory that can be placed there. Each storage area should be clearly labeled. Outlining is also used to clearly show aisle ways, electrical panels, and locations of potential safety hazards.

* It's a good idea to develop a color code strategy for marking your floors and then standardize it. Color coding your tooling also has some great potential. This example shows how the tooling is color coded by the radius size of the tooling.

* Tool boards also have great potential for a visual workplace. You can outline the tools and label them so they are easy to find and put away. You can also see if a tool is missing from 20 feet away. Just keep in mind that shadow boards may not always place the tools as close to the point of use as possible based on the frequency of their use.

* Where storage locations might change slightly, consider portable labels. For example, magnetic labels work extremely well on metal racking, drawers and metal storage racks.

* It would be very difficult to find the item you need and put it away again in this tool cabinet without proper labeling, and even with proper labeling, there is absolutely no visual control at all. Here is a great example of tool organization and labeling. The use of Plexiglass keeps the tools clean and it makes the tool storage very visual. Setting the shelves at an angle also makes the tools even more visual.

* Set in Order eliminates many kinds of waste as follows:

A: The waste of searching is eliminated by locating items where they are easy to find and put away again.

B: Motion waste is eliminated when we eliminate the waste of searching. Motion waste is also reduced when we place tools at the point of use and change the layout of equipment and machines to create flow.

C: The waste of human energy and frustration is eliminated when items are easy to find and we have a less stressful environment to work in.

D: The waste of excess inventory is eliminated by creating specific locations for your inventory with only enough space for the items we need.

E: The waste due to difficulty in returning items is eliminated when we make it clear where items belong and it becomes easy for anyone to return items.

F: The waste of unsafe conditions is eliminated when aisle ways are clearly marked

G: Along with fire extinguishers, first aid kits and other safety items being clearly marked.

H: This results in decreased medical and insurance costs

I: The waste of defective products decreases as our work areas are organized and efficient.

J: Productivity increases when machines are moved to create flow and all of the above wastes are eliminated

K: Employee satisfaction increases as it becomes faster and easier to do their job.

L: And last, bottom line profitability increases from all of these efforts.

 

* Set-in-Order is probably one of the most difficult steps to implement on the shop floor. It requires a tremendous amount of time, a lot of planning and hard work, top management support, lots of teamwork and plenty of creativity.

 

Most companies fail to implement set-in-order properly because it is so all encompassing, so if you need help with 5S training and/or implementation, give us a call today, and don't forget to check out the other videos in the 5S Series.

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* 5S is an integral part of Lean Manufacturing since it focuses heavily on the elimination of waste. Shine is the housekeeping portion of 5S and this video will teach you how to implement Shine at your company so you may realize all of the benefits 5S has to offer.

* In review, the 5 S's are Sort, Set-In-Order, Shine, Standardize, and Sustain in that order. We will now focus on Shine for the remainder of this presentation.

* By implementing 5S Shine you can turn a terrible workplace where no one wants to work, into an enjoyable workplace where people are happy to come to work each day. Before Shine, our workplace can look dirty and dingy. But our workplace improves gradually as we sweep the floors, mop the floors, and even polish the floors until they shine. We also clean the surfaces of everything including machines, tables and cabinets. Remove dust from every surface and clean the windows and skylights so they will let in natural light. Cleaning the windows, skylights, walls, and other surfaces makes the environment brighter and easier to detect quality defects that might otherwise have gone undetected.

* And last, cleaning the machines is a big part of Shine because as we clean the machines, we will be able to easily inspect them. Cleaning and maintaining the machines is one of the most tangible benefits of shine. Here is an excellent example of a filthy machine before Shine. If this machine had any oil leaks, you would never be able to find them in this condition.

* After Shine this machine looks brand new. Any oil leak would stick out like a sore thumb and that is exactly what you want. While we clean the machines in our area, we must inspect them closely so we can take greater care of them. We can ensure that:

A: There are no loose nuts or bolts

B: Make sure gauges are legible, working properly, and within the acceptable range specified

C: Check the condition of the motor

D: Feel for any heat that might be excessive

E: Check all of the fan belts or other belts for proper tension and excess wear

F: Feel the equipment for excess vibration

G: Smell for anything out of the ordinary especially something burning.

H: Listen for any sounds that are not normal to the operation of the equipment.

I: And look for water, oil, hydraulic, or air leaks.

 

* When we clean the machines we will uncover various leaks that had previously gone undetected. Any liquids leaking on the floor can cause people to slip and injure themselves. And leaks can also cause people to get shocked. Machines that leak oil make a mess of the machine itself and the surrounding area.

* Oil leaks can also cause machines to overheat and wear out quickly because of the lack of oil. Oil leaks also cause people to have to replace the oil frequently and don't forget about the cost of the oil itself.

* If you find your equipment needs to be repaired, every company has a different set of rules to follow, but as a guideline, you want to do it yourself immediately if you are fully capable of doing so. But if the problem is beyond your capabilities, call in a professional. Poorly maintained machines will break down more often and at the worst times.

* When machines are not running productivity automatically goes down. And that causes the boss to get upset, not to mention how the customer is going to feel when they find out their delivery is going to be late because your machine is not running.

* Shine can help eliminate another problem and that is FOD or foreign object damage.

* For example: metal shavings left on workbenches or other surfaces can damage your products. This shipping container used for transporting product is filled with debris and metal shavings that will damage the product when placed inside and transported. Foreign object damage can cause costly rework or scrap. Nobody really likes to clean without being told, so there are some key steps to make Shine work for you. First, you need to make a list of the items to be cleaned in the area. And determine the method of cleaning and add that to the list you just created. For example, mop with soap and water, or use spray cleaner brand X, etc.

* You then need to make assignments for cleaning and make it very visual as to who is responsible for cleaning what and when as in this assignment board showing pictures of the responsible individuals.

* When you organize your cleaning supplies, use the Set-in-Order phase of 5S. This way everyone will know where the cleaning supplies are and where to put them when they are done. Make sure that any chemicals or cleaners used are clearly labeled.

* And finally, it's time to start shining. Once you implement Shine, you will realize the following benefits:

Morale improves as employees are happy to work in clean work environment.

Quality improves as defective products are easier to catch in a clean bright environment.

Your workplace will be much safer meaning less accidents, fewer injuries, and lower medical costs. Insurance costs are also reduced.

 

* Cleaning and inspecting the equipment means more reliable equipment which results in:

Less production downtime

And that means Higher machine uptimes

More on time deliveries, and higher productivity

 

* Customers and potential customers can't help but notice what a great workplace you have. And best of all, these improvements equate to more money added to the bottom line.

 

The road to Lean is paved with 5S. So if your company wants to become Lean, this is a great place to start your journey. Shine is not easy, and neither is implementing any aspect of 5S, so if you need help training employees or implementation give us a call today. We're the guys who make this process simple!

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5S sort

 

* 5S is an integral part of Lean Manufacturing. This presentation will focus on sort which is first S in the 5S process.

* It might be helpful to first watch our 5S Overview Video if you have not seen it previously.

* In review, the 5S's are sort, Set in Order, Shine, Standardize, and Sustain in that order. Let's focus on sort for the remainder of this presentation.

* Everyone can relate to a messy garage and that can be compared to our workplace. We gather too many things over time and pretty soon we can barely walk around. If you had to work in this environment, think about:

A: How much time would you spend looking for the things you need?

B: How efficient you would be, or in other words, how long it would take to complete a project?

C: How safe of an environment is it?

D: And how frustrating might the experience be?

 

* Many companies tolerate these conditions in the workplace because they do not understand the extent of the waste and the consequences involved.

* In order to clear the area you have to define what is needed in the immediate area. When you do this, consider:

A: Cabinets

B: Paperwork

C: Gauges

D: Machines and equipment

E: Packaging Materials

F: Parts and assemblies

G: Blueprints

H: Shelving

I: Supplies

J: Tables

K: Tooling

L: Towels

M: And even trash

 

* Let's create a department we can use as an example that needs to be sorted out. In this department, we have:

A: Machines

B: Workbenches

C: Tool Boxes

D: Supply Cabinets

E: Work in Process

F: Chairs

G: Trashcans

H: Tools

I: Paperwork

J: And Pallets

K: This example is fairly typical for a department in a manufacturing company.

 

* Now it's time for that first big step. Figuring out what stays and what goes. Don't go it alone. sorting is a team sport, and if second or third shifts are involved, make sure you include them in sorting and every aspect of 5S. There are some territorial issues involved with all aspects of 5S, so it is best to work together as a Team.

* Here are some guidelines for making good decisions:

A: The 48 hour rule says that if you are going to use it for production within 48 hours it belongs in the area.

B: The concept of sort is similar to the Just-In-Time principle as they both teach only what is needed, only in the amounts needed and only when it is needed

 

* Another guideline is based on frequency of use. The less frequently an item is used, the farther from the work area it should be stored, for example:

A: Items that are used daily should be stored in the immediate area

B: Items that are used weekly should be stored near the area

C: Items that are used monthly or less frequently should be stored in a remote location.

 

* Make a list of everything in the area and the frequency of use such as daily, weekly, or monthly. Make sure this is a team effort.

* Then disposition the items on the list as follows:

A: Item to stay in the area

B: Item to be stored near the area

C: Item to be stored in a remote location

D: Item no longer needed

 

* When items have been dispositioned as no longer needed, a red tag system is used for several reasons:

A: To identify the item

B: Where the item came from

C: Who created the red tag

D: And the date the tag was created

 

* If the disposition is the item is no longer needed, you might want to consider:

A: Placing the items in a red tag hold area for six months before taking any further action

B: Hold an auction with the key people at your company to see if any other department needs the item

C: After that either sell it

D: Give it away to charity

E: Or put it in the trash

 

* Now that dispositions have been made, it's time to start clearing out the area. Let's see what a difference it makes with our example department:

A: It's not uncommon to have machines that are no longer needed or used, but no one can bear to remove them. This machine is no longer needed, so we are removing it and the workbench next to it.

B: The amount of work in process needed in an area will vary, but remember, your department is not a storage area so get extra WIP out.

C: Storage cabinets have a way of collecting lots of unneeded items, so it's best to get them out.

D: Personal tool cabinets take up a lot of room and the tools are only available to one employee and the tools cannot be placed at point of use.

E: Extra pallets can be removed from the area and if needed, a location can be created for them to be stacked up.

F: Chairs are seldom necessary in a Lean environment. Chairs detract from flow and an efficient process.

G: Extra tools that are not immediately needed can be removed

H: As well as the extra trashcan

I: Finally, we have removed any paperwork that is not needed for current production

J: You can clearly see the amount of extra space you now have for production or additional equipment, which will increase your capacity. You can now see the possibilities of re-arranging this department to make it more efficient. That is where set-in-order comes into play.

 

* The benefits of sort are many:

A: First of all, it is quite a bit easier to just move around in the area

B: And that means less things in the area to trip over, meaning less accidents

C: sorting typically removes barriers that might have built up over the years

D: And that helps to improve communication

E: Employees don't have to search nearly as much to find what they need

F: So the time it takes to set-up machines or equipment decreases along with the searching time.

G: This causes Productivity to increase

H: And the waste of human energy and frustration decreases

I: And we can put a few extra dollars in our pocket by eliminating these wastes.

 

* Remember, 5S is not easy. If it were, everybody would have done it already. But as you can clearly see, the benefits of sort are worth the effort it takes to implement.

We hope you have enjoyed this presentation. Look for the other videos in the 5S series on Set-in-order, shine, standardize, and sustain. And if you need help training employees or implementing 5S visit us at xtremelean.us .

We're the guys who make this process simple!

Improving Business Performance with Ease, Part 1 by xtremelean.us

* Welcome to Part I of a six-part video series where I will show you how you can transform your business by implementing a customized business performance measurement system that will improve your business performance to World Class levels never before dreamed of.

* Every business is comprised of many different processes, and as an example, here are the functions that make up the value stream for one particular company, and each function has multiple processes.

* There is one guarantee I can make to you. Every process or aspect of your business within your company is either improving...

* Or it is getting worse

* But it is definitely NOT staying the same.

* So how well are you tracking every aspect of your business?

* To be highly successful in business, you must have your fingers on the pulse of all of aspects of your business continually. Most companies struggle because they have no easy way to do this.

* The business decisions you make should be based on data and not on gut feelings.

* When we have access to good data, good decisions can be made. And when good data is arranged in a graphical format that is easy to understand and analyze, we can make good decisions quickly.

* Good and fast decision making means rapid improvement for all aspects of your business.

* It also means your business will be completely proactive, or acting in advance to deal with expected difficulties. You will no longer be in a reactive mode where you wait for problems to occur before taking action.

* Being reactive is also known as firefighting and most companies even have people that are experts at fixing problems after they have occurred. When you become proactive, you can prevent all of the costly firefighting.

* Being proactive also eliminates the finger pointing, frustration and chaos at all levels of the organization.

* Rapid improvement is also synonymous with making money. Is your company a money making machine where profitability is always high? Or does your company struggle with cash even when business is really strong?

* Did I mention this performance measurement system is totally automated? All you need is Microsoft Office Excel 2007.

* The bottom line is you can take the data on your company's server, and upload it into automated charts that will never need to be maintained again. The data will refresh and update the chart automatically.

* If you think this looks too complicated for you, don't worry. I will make your learning experience easy.

* The burning question is, are you ready for your business to improve to world class levels? If so, welcome to the rest of this presentation.

* The foundation of this performance measurement system will be the five phases of Six Sigma:

Define, Measure, Analyze, Improve and Control.

The five phases of Six Sigma are also referred to as the DMAIC process. The DMAIC process lends itself perfectly to establishing and maintaining a business performance measurement system that can be used to improve all aspects of your business concurrently, continuously, and with relative ease.

* Now in the remainder of this presentation "Define", we will discuss setting business goals that are key and that reflect the values of the shareholders and top management, and setting up a performance measurement system structure to support and achieve those goals.

* The process starts by determining what your business values are, and turning them into SMART and sustainable goals.

* I will then explain the support structure that directs the energy from all of your employees like a laser towards the achievement of your business goals.

* Having appropriate goals for any business is key if you want to be successful in this global marketplace. Determining goals is also the keystone of the structure for supporting and achieving your companies goals.

* Goal setting is not easy and it requires more than a crystal ball if you want to be successful. Let's say you would like to set as your goal to grow the business by 30% next year.

* If you look at last years performance trend and it showed your business was actually declining, setting a goal of 30% growth may not be attainable.

* But if lasts years performance trend showed you grew the business by 30% the year before, it may very well be possible to continue that growth pattern. The bottom line is, goal setting should be based on good information or data to establish an effective and attainable goal.

* Goals must be SMART and that means:

Specific - goals must be specific rather than vague. For example, I want to improve our on time delivery performance to 99%.

Measurable - In this instance it means you need to be able to measure what your on time delivery performance is. If you can not measure it you can not manage it.

Attainable - This is tricky. If you set a goal that is absolutely unattainable, employees will become discourage because they will feel they have failed. On the other hand, if you set a goal that is too easy to reach, once the goal is reached, people stop trying to improve.

Realistic basically means the goal is manageable and will support the high level goals of the company.

Time bound - which means giving your goal a target completion date such as by the end of the fiscal year.

 

* Stretch goals are objectives that seem impossible under the present circumstances, but setting stretch goals can cause people to think outside the box and develop ideas to improve performance dramatically.

* Business goals are at a very high level and should be based on what the company values and what is most important to them.

* Every company will have a different set of values and goals, but I will give you examples of some worthy goals that a company might strive for:

Customer satisfaction

Quality

On-Time delivery

Shareholder satisfaction

Employee satisfaction

Market Share

Growth Rate

And Profitability

 

* You may choose any set of goals that align your company with its values.

* Let's pretend for a moment that these are your companies values. I will now show you how to turn these values into the businesses high level goals.

* Let's take one of our high level values "Customer Satisfaction" and turn it into a SMART goal.

* First our goal must be specific. Customer Satisfaction is probably one of the hardest values to measure. In this case, I would recommend sending surveys to your customers regularly, or better yet using a survey service like "Survey Monkey" to perform automated surveys regularly. Getting actual responses from your customer would be the best way to judge their level of satisfaction. So let's set a specific goal of wanting the customer surveys to come back at 90% satisfied at least to start with.

* Design the survey to the customer so their responses are measureable such as "on a scale from 1 -10 how would you rate our customer service" and so on. Also decide how often you will send the surveys out.

* Be careful when setting the goal at 90%. You want to have to stretch, but you also want the goal to be attainable.

* Ensure the goal is realistic and manageable. Does your company have the resources to create an on-line survey to send to your customers? Do you have the resources to analyze the feedback and make the necessary improvements?

* Making the goal time bound means giving yourself some time to reach the goal of 90%. For example you may say you want to reach your goal of 90% by the end of the year.

* Now let me introduce you to the support structure that directs the energy from all of your employees like a laser towards achieving your SMART business goals.

* Now that SMART goals have been established based on the true values of the company. They must be supported by all applicable aspects of the business if they are to be attained. The operational metrics are the first line of support for the goals and values of the company. What can the entire company do to help ensure the customer surveys are returned at a 90% level or higher?

* Customers are looking for just three things. They want products with high quality, with world class service at an affordable price.

* In this case, Operations can track several areas that will support the companies high level goal of customer satisfaction. They can track the outgoing quality levels to the customer and the on-time delivery performance to the customer. Product costs can be reduced many ways, but increasing productivity and reducing inventory levels just a couple of examples of reducing product costs which in turn can reduce the cost to the customer. Customer service can play an important role in treating the customer like a King and there are many ways to accomplish this. So as you can see, this one high level goal of customer satisfaction is now being supported by five clear and measureable goals by the folks responsible for operations.

* For every high level goal, there is a flow down to operations of several measurements that will support and help achieve the high level goal.

* Operational metrics or measurements seldom mean anything to operators that are actually responsible for manufacturing the products. Each cell or department must know exactly how they are performing to help support and achieve the operational metrics. Hence the need for Cell or Department measurements.

* Let's again just take one example from the Operations Metrics "Productivity" and see how each Cell or Department can support it and track their productivity separately. The Cell or Department Leaders would be responsible for tracking. And remember, each must have a SMART goal. You now have five cells that know what their productivity level is relative to their goal, and whether they are successful or if there is improvement needed. No questions. Each cell also knows how they are affecting the Operations metrics in regards to productivity and the effect it has on customer satisfaction. Operations also knows exactly how each department is doing and how it is affecting their operational goal.

* The cell or department leader must also have the ability to know the productivity of each member in their area. You can now see how each and every high level company goal can be supported and achieved by every person within your business.

* This is the performance measurement system structure that will support and help you achieve your goals and objectives and make your business a thriving success.

* Next up in our video series is the Measure section, or Part II, where we will discuss:

The sheer power of measurements by themselves

Setting up charts to make them easy to analyze while also getting the most information possible

And what can happen when charts are made visible and employees are taught how to read them.

* I hope you have enjoyed this presentation. Once again, this was Part I of Six, so stay tuned for the rest of the series.

 

In the meantime, if there is anything I can do to help you improve your business, visit my website at www.xtremelean.us

Lean Business and Manufacturing Overview by xtremelean.us

 

* This presentation is an overview of Lean Business and Lean Manufacturing.

* Lean Business can be compared to our bodies. If we are athletic, we are considered to be lean. If we are not athletic, we are not lean. When we are not lean, we are sluggish and lack energy. For example, it is very difficult to run when we are unfit as opposed to being in good physical shape. Let's explore this concept a little further.

* A Lean Company is considered to be:

A: Fast

B: Strong

C: Agile

D: Coordinated

E: Ready for anything

F: Promotes teamwork

G: Has a lucrative business

H: And in general, a winner

 

* On the other hand, a non lean company is considered to be:

A: Slow

B: Weak

C: Clumsy

D: Uncoordinated

E: Not ready for anything

F: Severe lack of teamwork

G: Cash poor

H: And in general, a loser

 

* Every company is made up of several business processes that are linked together as shown in this example.

* The first reason many companies fail to become lean is they focus their attention solely on manufacturing, rather than the entire business.

* Let's take a look at the process flow for manufacturing as an example.

* The green areas represent value added work, whereas the red areas represent all of the wastes found in manufacturing.

* The amount of actual value added work adds up to a very small 1 - 5% of the time spent in manufacturing

* The second reason many companies fail to become lean is, they focus their efforts on improving only the value added work they perform, instead of reducing or eliminating all of the waste in the process. Making improvements on the value added work gives a very small return as shown here.

* Within manufacturing, let's focus our attention on the non value added work, or wastes that extend the lead time unnecessarily. Remember, this represents 95 - 99% of the time spent in manufacturing.

* There are seven predominate wastes in manufacturing processes, and I will give some examples of each.

* If you see product sitting on your shop floor waiting to be processed you have excess inventory or excess work in process. While it sits on the shop floor you are not adding value to it.

* If you have to remove rust or dust from products because of the length of time they spent in your manufacturing process, you are over processing.

* If you have to wait for anything including waiting for set-ups, inspection, or other downtime, this is the waste of waiting.

* Any walking the operators have to do is a good example of wasted motion. Walking never adds value to the product.

* If you produce more parts than what the customer needs because you want to take advantage of the set-up, that is overproduction. Long set-up times are the cause of overproduction.

* Defective products have to be either reworked or scrapped. Defective products take a substantial amount of time away from production.

* If you move product with forklifts or conveyors your process includes excess transportation, which is usually caused by a poor layout of equipment and machines.

* To become lean you must focus your efforts on both the value added and non value added steps in your process. Reduce or eliminate as much of the waste as you possibly can, and make improvements on the value added work to reduce the lead time substantially.

* There are many steps in the business process that contribute to the overall lead time. To reduce total lead time we have to focus efforts in more areas than just manufacturing. If waste is eliminated at every business process, total lead time can be drastically reduced. Kaizen Events are one of the best ways to identify and eliminate waste.

* Search for waste in your business and look at all of your business processes, not just manufacturing. Sometimes waste is disguised as value added work and can be difficult to find, so be diligent and ask lots of questions.

* Perform a comprehensive lean assessment on your business. A fresh set of eyes can be extremely helpful when it comes to an accurate lean assessment. We specialize in quick yet thorough lean assessments.

* When performing an informal self assessment of your company, you might want to ask yourself these questions:

A: Do we deliver quickly and on time to our customers, or are we slow, our deliveries late and customers are upset?

B: Is my business strong and do we value our employees, customers, and suppliers, or are we weak and just taking care of number one?

C: Is my company flexible? Can we respond effortlessly to changes in customer demand and marketplace? Or are we inflexible and clumsy?

D: Are all the processes in my business well coordinated or is coordination a foreign word?

E: Is my company always ready for continuous improvement efforts, or is my company never ready or willing to change?

F: Is teamwork a way of life at my company or is there a lot of infighting?

G: Are we lucrative and put money back into the business regularly, or do we struggle to make ends meet?

H: And in general, is my company a clear winner, loser, or somewhere in-between.

 

Remember, when it comes to business, you want to be a winner, not a loser, so visit us at www.xtremelean.us and we can help you transform your company into a lean, mean, money-making machine.

# This is an overview of 5S with its associated benefits.

# There are many that believe 5S is just about housekeeping. This is a myth that will soon be busted.

# The 5S's are sort, set in order, shine, standardize, and sustain in that order and starting with sort.

# To sort, you first have to determine what is needed and not needed in the area. Consider equipment, tools, materials, supplies, and even paperwork.

# The benefits of sort are:

A: More floor space, which leads to less things to trip over.

B: Less wasted motion increases productivity

C: sorting may even improve health conditions

 

# Set in order includes determining the best locations for machines and equipment. Here is an example of a department before 5S, and after.

# Set in order includes determining the best locations for tools. Making tools easy to find and put away and clearly labeled. Tools should be stored at the point of use. If a wrench is needed to adjust this machine, it should be stored as close to the point of use as possible.

# Creating locations for everything in the area and labeling them is another part of set in order.

# Some of the benefits of set in order include the elimination of Searching Waste - looking for needed tools is a waste of motion, and less wasted motion means higher productivity and faster set-up times.

# Shine actually does have to do with housekeeping and that is where the myth comes from. shine includes cleaning the floors, the surfaces of everything, cleaning the windows will let natural light in, and cleaning machines will make it easy to inspect the machines for leaks or other maintenance problems that need to be addressed.

# Some of the benefits of shine include:

A: Safer conditions when we keep oil and liquids off the floor.

B: Better equipment reliability when we keep it clean and maintained.

C: And employees are happier when then have a clean work environment to come to each day.

 

# Standardize means everybody doing things the same way when it comes to sort, set in order, and shine. There are many possibilities for standardization, and I will give you just a few examples. When it comes to sorting for example, the same red tag system and procedure should be used. Setting in order can be standardized in the way we mark our floors and the way we locate our tools. shine can be standardized in the cleaners we use and how we label them, to the way we store them. We can also have a standard approach to problem solving when we encounter problems with sort, set in order or shine.

# The benefits of standardizing are everything is done the same way by everyone, and everyone understands what to do and how to do it.

# 5S is as difficult to sustain as keeping up an exercise program. If we do not continue exercising, we go back to the way we were before we started. 5S is as difficult to sustain as eating properly, if we do not continue, we again go back to the way we were. Here is an example of sustaining a healthy body, and not sustaining. sustained flight...and not sustained flight. If we do not sustain 5S, our company will revert back to the way it was before we started.

# The benefits of sustain are you get to enjoy all of the benefits of 5S forever:

A: Less Wasted Motion

B: Less Searching Time

C: Less Accidents

D: Lower costs

E: Increased productivity

F: Higher Quality

G: Employee Satisfaction

 

#

# 5S will help you on your road to Lean. Many of the wastes that need to be eliminated in manufacturing can be eliminated through 5S.

# Remember, 5S is not easy, but good things never are. The benefits far exceed the hard work required to achieve 5S.

This 5S Videos Series is also available in Spanish!

If you need help in training or implementing 5S, please visit us at www.xtremelean.us . Also, look for additional videos for sort, set in order, shine, standardize, and sustain.

5S Overview Video by xtremelean.us

* This is an overview of 5S with its associated benefits.

* There are many that believe 5S is just about housekeeping. This is a myth that will soon be busted.

* The 5S's are sort, set in order, shine, standardize, and sustain in that order and starting with sort.

* To sort, you first have to determine what is needed and not needed in the area. Consider equipment, tools, materials, supplies, and even paperwork.

* The benefits of sort are:

A: More floor space, which leads to less things to trip over.

B: Less wasted motion increases productivity

C: sorting may even improve health conditions

 

* Set in order includes determining the best locations for machines and equipment. Here is an example of a department before 5S, and after.

* Set in order includes determining the best locations for tools. Making tools easy to find and put away and clearly labeled. Tools should be stored at the point of use. If a wrench is needed to adjust this machine, it should be stored as close to the point of use as possible.

* Creating locations for everything in the area and labeling them is another part of set in order.

* Some of the benefits of set in order include the elimination of Searching Waste - looking for needed tools is a waste of motion, and less wasted motion means higher productivity and faster set-up times.

* Shine actually does have to do with housekeeping and that is where the myth comes from. shine includes cleaning the floors, the surfaces of everything, cleaning the windows will let natural light in, and cleaning machines will make it easy to inspect the machines for leaks or other maintenance problems that need to be addressed.

* Some of the benefits of shine include:

A: Safer conditions when we keep oil and liquids off the floor.

B: Better equipment reliability when we keep it clean and maintained.

C: And employees are happier when then have a clean work environment to come to each day.

 

* Standardize means everybody doing things the same way when it comes to sort, set in order, and shine. There are many possibilities for standardization, and I will give you just a few examples. When it comes to sorting for example, the same red tag system and procedure should be used. Setting in order can be standardized in the way we mark our floors and the way we locate our tools. shine can be standardized in the cleaners we use and how we label them, to the way we store them. We can also have a standard approach to problem solving when we encounter problems with sort, set in order or shine.

* The benefits of standardizing are everything is done the same way by everyone, and everyone understands what to do and how to do it.

* 5S is as difficult to sustain as keeping up an exercise program. If we do not continue exercising, we go back to the way we were before we started. 5S is as difficult to sustain as eating properly, if we do not continue, we again go back to the way we were. Here is an example of sustaining a healthy body, and not sustaining. sustained flight...and not sustained flight. If we do not sustain 5S, our company will revert back to the way it was before we started.

* The benefits of sustain are you get to enjoy all of the benefits of 5S forever:

A: Less Wasted Motion

B: Less Searching Time

C: Less Accidents

D: Lower costs

E: Increased productivity

F: Higher Quality

G: Employee Satisfaction

 

*

* 5S will help you on your road to Lean. Many of the wastes that need to be eliminated in manufacturing can be eliminated through 5S.

* Remember, 5S is not easy, but good things never are. The benefits far exceed the hard work required to achieve 5S.

This 5S Videos Series is also available in Spanish!

If you need help in training or implementing 5S, visit us at www.xtremelean.us . Also, look for additional videos for sort, set in order, shine, standardize, and sustain.

About Xtreme Lean Consulting

Welcome to our website where you will find valuable information about Lean Business practices, Lean Manufacturing, Six Sigma Quality, and how we can implement solutions to improve your business.

 

Xtreme Lean Consulting is made up of expert consultants with many years of "hands-on" experience from the shop floor to Senior Management.

 

We understand the pressures and requirements of manufacturing businesses and the difficulty in improving the workplace. (Continuous Improvement)

 

We also understand every company is unique in its products, processes, culture, people, and the problems they face (Tailored solutions).

 

Working collaboratively with your company employees, we assess the current manufacturing and business processes from a Lean perspective. Together we develop a strategic plan for success, train and coach employees to implement improvements, and ensure goals are met and sustained (improvement).

 

We have consultants fluent in English and Spanish(communication) who are capable of working effectively at all levels of the organization. Our training materials are engaging and easily comprehended by all personnel. Watch samples of our training materials here on this website. (Training materials)

 

Working together you can expect our solutions to yield all of the following benefits:

 

* Higher productivity

* Higher quality

* Greater capacity

* Shorter lead time

* Reduced Inventory

* Higher profitability

* And increased customer satisfaction

  

We look forward to working with you to transform your company into a World Class business. Visit us at www.xtremelean.us

The Seven wastes Found in Manufacturing by xtremelean.us

 

* The Seven wastes Found in Manufacturing is an enlightening video that defines and gives examples of each waste with their associated consequences. waste elimination is key to any Lean organization.

* waste is the opposite of value and you should continue adding value while reducing or eliminating waste.

* There are typically seven types of waste found in manufacturing, and for the purposes of this presentation, I will assign an animation to represent each waste that will be used throughout.

1: Excess Inventories means holding or purchasing unnecessary raw materials, excess work in process or finished goods.

2: Unneeded Processing Time or Over-processing means having unnecessary steps, work elements, or procedures.

3: Waiting means time delays, idle time or time during which value is not added to the product, adding cost without creating value. Waiting lengthens the total cycle time unnecessarily.

4: Excessive Motion is the actions of people or equipment that do not add value to the product.

5: Overproduction can be early production, producing over the customer requirements, or producing unnecessary materials or products.

6: Defective Products means producing a part that is scrapped or requires rework, or consuming resources without making a product for the customer.

7: The waste of Transportation means multiple handling or unnecessary handling, and ultimately causes the delay of material delivery to next operation.

 

* These wastes do not add value to the product and must be identified and either eliminated or reduced. Your business will not reach its full potential when these wastes exist.

* Examples of excess inventories include:

A: Most of the work in process between operations also called "batch and queue" is excess inventory

B: And producing more than the customer demands causes excess inventories

 

* The consequences of having excess inventories include the waste of waiting. Watch this one batch of parts as it slowly makes its way through production. As you can see, all of the work in process between operations causes the lead time of each batch to increase drastically. Most of the time spent in manufacturing is waiting. All of that waiting causes longer lead times and delays.

* Excess inventory prevents problems from being detected quickly enough. In this example, let's pretend you are processing a 1,000 piece batch. The red ball represents your batch of material as it makes its way through the excess inventory. If the 3rd operation finds a problem with the 1st operation, you are looking at all 1,000 pcs being defective.

* Materials and labor are tied up in inventories sitting on the shop floor which is cash out of pocket.

* Excess inventory means having to handle the same material multiple times, stocking materials the customer does not need, controlling and counting inventory, and purging materials from stock.

* Lastly, excess inventories consume valuable floor space that could be used for additional equipment that can produce product and increase productivity.

* Examples of unneeded processing time or over processing include:

A: Sanding more than is required to produce an acceptable product

B: Applying more paint than is required

C: Having to remove rust or dust because of the length of time the product sat on the shop floor

D: Not having the right equipment to do the job, like using a machine for something it was not intended.

 

* When items are over processed:

A: It takes longer to produce the item so the lead time lengthens

B: It takes valuable time away from production, so productivity decreases

C: It is a waste of human energy and motion

D: And if we have to transport the items for an operation that is unnecessary, it is excess transportation

 

* Some examples of the waste of waiting are:

A: waiting while the parts sit in queue

B: The operator waiting for anything including inspection

C: Waiting for operators that are not meeting takt time for example

D: And the waste of watching any machine run

 

* The waste of waiting causes:

A: Longer lead times

B: A loss in productivity

C: And the start and stop prevents smooth production flow

 

* Some examples of excessive motion are:

A: Bending to pick up parts or tools

B: Reaching for parts or tools

C: And walking is by far the worst waste of excessive motion

 

* Excessive motion applies to both machines and to manpower and causes:

A: Longer lead times

B: A decrease in productivity

C: And poor ergonomics which can lead to safety concerns

 

* Overproduction is characterized by:

A: Making too many parts or producing parts before the customer requires them

B: Excessive scrap during set-ups cause us to produce more parts than are required

C: But long set-up times are the main culprit for producing more parts than are required. Long set-ups are a waste of time so production wants to make as many parts as possible before they tear down a setup, and that usually means producing more than the customer wants at that moment.

 

* Overproduction causes:

A: Longer lead time

B: Excessive inventories

C: wasted motion

D: And a decrease in productivity

 

* Some examples of defective products include:

A: Scrap

B: Rework

C: Customer complaints

D: And customer returns. Customer returns require processing, rework or remake, and sometime a formal corrective action process.

 

* When defective products are produced:

A: It costs money in materials and labor to rework or remake

B: It takes extra time away from production

C: Customer good will is lost

D: And the lead time is increased

 

* Examples of the waste of transportation can be found when we see conveyors (which are considered automated waste) and forklifts. The waste of transportation is caused by a poor factory layout.

* The waste of transportation causes:

A: A longer lead time

B: Transportation damage causing rework or scrap

C: And a decrease in productivity

 

* As you can see, all of these wastes are interrelated. You must continuously drive waste out of the factory and increase value to the customer. Remember, the customer is only willing to pay for value added activities and not waste.

 

Proper flow reduces all of the wastes discussed in this presentation. If you need to change the flow of your business, visit us at www.xtremelean.us

We're the guys who make this process simple!

El 5S es una parte esencial en la manufactura económica por eso es importante tener un buen conocimiento de este. Este DVD aclarara que es el 5S, como funciona, sus numerosos beneficios y como el 5S puede ser implementado en su negocio.

 

Usándose gráficos y animación para un fácil entendimiento los cuales ilustran por completo cada punto, este DVD hace más fácil para todo el personal comprender los principios del 5S. Ejemplos de clasificación, poner en orden, destacar, estandarizar y mantener , estos puntos son explicados en forma detallada, y como estos pueden ser aplicados para tu negocio.

 

5S te ayudara a eliminar en tu negocio la mayoría de los desechos encontrados en el proceso de manufactura. Cuando tu implementas el 5S y te conviertes en económico (lean) te darás cuenta de todos los beneficios que el 5S tiene para ofrecerte en tu negocio. Puedes comprar la versión completa de estos DVD visitando nuestro sitio web después tu también estarás en el tránsito para economizar mas negocios competitivos.

* Kanban is considered to be one of the central elements of Lean Manufacturing, and this presentation will explain some basics of what a Kanban System is, how it works, and how it can be implemented.

* I consider the definition of Kanban to be a signaling system that triggers more products to be produced and delivered. Our cars have a gas gage that works on the Kanban principle. It signals you when the gas has been consumed and more gas is required.

* One of the oldest examples of a simple Kanban system I can think of is the one used for home milk delivery. The process is simple and incredibly effective. The night before the milkman is scheduled to come, just place any empty bottles outside your door. The milkman picks up the empties and replaces them with full bottles of milk.

* Most companies use a Push Production System which is to produce product based on what they think is going to be consumed rather than what is actually consumed. Imagine trying to guess how much milk each customer is going to consume each day. If you are wrong, you will either be overproducing or under-producing. And guess what; your chances of being wrong are really high! Both over and under production have a negative impact on business and will be discussed later.

* The premise of Kanbans is that material will not be produced or moved until a customer sends the signal to do so.

* Kanban relates to the Just-in-Time principle of producing only what is needed, only in the amounts needed, and only when it is needed.

* Kanban production systems are also known as a pull production system because you are waiting for the customer to signal that product has been consumed and replacements are needed as in this milk delivery system.

 

Filming of internal training video for Barclays Bank

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About Xtreme Lean Consulting

Welcome to our website where you will find valuable information about Lean Business practices, Lean Manufacturing, Six Sigma Quality, and how we can implement solutions to improve your business.

 

Xtreme Lean Consulting is made up of expert consultants with many years of "hands-on" experience from the shop floor to Senior Management.

 

We understand the pressures and requirements of manufacturing businesses and the difficulty in improving the workplace. (Continuous Improvement)

 

We also understand every company is unique in its products, processes, culture, people, and the problems they face (Tailored solutions).

 

Working collaboratively with your company employees, we assess the current manufacturing and business processes from a Lean perspective. Together we develop a strategic plan for success, train and coach employees to implement improvements, and ensure goals are met and sustained (improvement).

 

We have consultants fluent in English and Spanish(communication) who are capable of working effectively at all levels of the organization. Our training materials are engaging and easily comprehended by all personnel. Watch samples of our training materials here on this website. (Training materials)

 

Working together you can expect our solutions to yield all of the following benefits:

 

* Higher productivity

* Higher quality

* Greater capacity

* Shorter lead time

* Reduced Inventory

* Higher profitability

* And increased customer satisfaction

  

We look forward to working with you to transform your company into a World Class business. Visit us today at xtremelean.us

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Filming of internal training video for Barclays Bank

If you frequent high end cafes, you will most likely come across or hear the term “Micro-Mill” used more and more often. A micro-mill is a washing station called a “Beneficio” which is located on a farm. Farms which have their own beneficio’s are able to have complete control over their quality. They are able to grow and harvest their coffee properly, wash & de-pulp their coffee, followed by drying their coffee before bringing it to the dry-mill which we discussed in our last blog post.

 

Through working with a properly run wet-mill a roaster is able to be more selective in the coffee we choose. Choosing a single varietal coffee, a specific lot/area of the farm and if we prefer to have our coffee processed a certain way in order to give it a unique flavor is all possible through the micro-mill.

 

But, there are years worth of work before coffee is ever harvested. Watch this new training video which walks you through the steps, and years of work required before coffee every gets tasted.

Wing Chun Club Placerville Chapter - Pole Form, massive martial arts power from the Wing Chun Pole Form. Great self defense training from wingchunclub.com with lots of valuable video and instructional information. 2nd Generation Yip Man via Grand Master Chris Chan of US Wing Chun Academy, Sifu SF. Zeigler of Wing Chun Club.

Many VHS tapes sit in an office under debris from a fallen ceiling and on the tops of old filing cabinets, alongside schematics and unwanted paperwork.

 

Many have mold inside their cases and on the tapes themselves, though amazingly some still played almost perfectly (in a tape player I brought with me to the plant).

Takt Time Video by xtremelean.us

* This is a short presentation that will show how to calculate takt time, determine the number of people needed to meet takt time, and how to balance the workload.

* To calculate takt time you need to know how much time you have available for production each day, and what your customer demand is per day.

* If you have 16 hours of production time available per day and your customer is demanding 1,000 units per day, convert the hours to seconds, because takt time is expressed as seconds per piece

* Then divide by the demand to get your takt time. In this case the takt time is 57.6 seconds for each unit

* Now that you know the takt time, or in other words, how often you have to produce one unit, what is the next step?

* First of all you need to know how many people will be required to meet that takt time.

* To find out how many people you need you must know how much work content there is in each unit.

* The work content is the total time it takes to build one unit. If one unit takes 9 minutes and 18 seconds for example, convert that to seconds, then divide that by your takt time to find out you need 9.69 people. Round that up to 10 people needed for production to meet takt time.

* You can begin to balance the workload now that you know what your takt time is, how much work content there is, and how many people you need to meet takt time.

* To balance the workload it is important to know how many steps there are in the work content and how long each step takes.

* As you can see, there are seven steps to assembling this one unit and the graph also shows how long each step takes in seconds.

* For this example you have 10 operators, and each operator has just under 60 seconds of available time per unit to contribute.

* You begin by assigning operators to work steps, and in some cases it will take more than one operator per work step as you see here.

* You will see that some operators will have available time on their hands as shown, and some operators are going to need some help.

* To help balance the workload you have the operators with available time help those that need it as shown.

* There are endless possibilities for laying out the assembly flow and I would classify them as good, better and best. The best layout is going to be the one that has the least wasted motion.

* Layout your assembly flow properly, because not meeting takt time can have severe consequences.

 

If you need help with your assembly flow, or with meeting takt time, or simply don't like being tased, visit us today at www.xtremelean.us

We're the guys who make this process simple!

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Filming of internal training video for Barclays Bank

BOMCAS LTD www.bomcas.com

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Record and Live Stream your event today, increase your market share.

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BOMCAS LTD www.bomcas.com

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Record and Live Stream your event today, increase your market share.

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Filming of internal training video for Barclays Bank

Laura Goodrich is an internationally recognized expert in the field of

workplace dynamics, change and the future of work. She has twenty

five years professional experience; 15 of which she has spent as a

corporate trainer, coach, consultant, and speaker.

Laura’s business stories and experience from all over the globe have

earned her the reputation as someone who can assist others in creating

positive business outcomes in even the most challenging workplace

dynamics.

 

BOMCAS LTD www.bomcas.com

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Whatever your event is we photograph, record and broadcast live to your desired platform.

 

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#Montreal #Camrose #Chestermere #ColdLake #FortSaskatchewan #Saskatchewan #GrandePrairie

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Filming of internal training video for Barclays Bank

House designed by OSCAR E FLORES DESIGN STUDIO

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Photographer and Videographer Sherwood Park Alberta Canada

  

Record and Live Stream your event today, increase your market share.

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Whatever your event is we photograph, record and broadcast live to your desired platform.

 

Edmonton Videographer & Video Production

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#Montreal #Camrose #Chestermere #ColdLake #FortSaskatchewan #Saskatchewan #GrandePrairie

#Lacombe #Leduc #Lethbridge #Lloydminster #MedicineHat #RedDeer #SpruceGrove #Wetaskiwin

#NovaScotia #NewBrunswick #Manitoba #PrinceEdwardIsland #NewfoundlandandLabrador

#NorthwestTerritories #Yukon #Nunavut #Victoria #Winnipeg #Fredericton #StJohn's

#Halifax #Charlottetown #Regina #Whitehorse #Iqaluit #Yellowknife #Moncton #Saskatoon #Montreal

#Niagara #Waterloo #Windsor #Sarnia #Kingston #Burlington #Brampton

  

#BOMCAS #Photographer #Videographer #SherwoodPark #Alberta #Canada #LiveStream

#event #Marketing #SocialMedia #Video #videography

#Photography #photo #videogtapher #videography #Livebroadcast #Concert #Wedding #Weddingphoto

#weddingvideo #weddingphotogyapher #weddingvideo #weddingplanning #weddingmakeup #marketingvideo

#weddingvideographer #Graduation #Funeral #videoproduction #videoediting #ads #advertisment

#videorecording #music #party #partyphoto #partyvideo #musicvideo #church #videocourse #safetytraining #trainingvideo

#Realestate #realestatephoto #realestatevideo #virtual #virtualtour #safety #Edmonton

#canada #toronto #ontario #calgary #sherwoodpark #bc #nature #wildlife #wildlifephoto

 

BOMCAS LTD www.bomcas.com

Photographer and Videographer Sherwood Park Alberta Canada

  

Record and Live Stream your event today, increase your market share.

•Business Marketing

•Social Media Marketing\management

•Increased Attendance

•Better Marketing Efforts

•New Revenue Opportunities

•Audio Recording

•Video and Photography

•Live stream\broadcast event

•Concert

•Wedding

•Graduation

•Funeral

•Video Recording/Editing

•E-Learning course

•Safety Training course

•Virtual tour

 

Whatever your event is we photograph, record and broadcast live to your desired platform.

 

Edmonton Videographer & Video Production

Sherwood Park Photographer & Video Production

  

#AudioRecording #Edmonton #toronto #london #calgary #stAlbert #canada #Reddeer #fortmcmurray #yeg #Vancouver

#Kitchener #Ontario #Winnipeg #Manitoba #Hamilton #Quebec #Ottawa #BritishColumbia

#Montreal #Camrose #Chestermere #ColdLake #FortSaskatchewan #Saskatchewan #GrandePrairie

#Lacombe #Leduc #Lethbridge #Lloydminster #MedicineHat #RedDeer #SpruceGrove #Wetaskiwin

#NovaScotia #NewBrunswick #Manitoba #PrinceEdwardIsland #NewfoundlandandLabrador

#NorthwestTerritories #Yukon #Nunavut #Victoria #Winnipeg #Fredericton #StJohn's

#Halifax #Charlottetown #Regina #Whitehorse #Iqaluit #Yellowknife #Moncton #Saskatoon #Montreal

#Niagara #Waterloo #Windsor #Sarnia #Kingston #Burlington #Brampton

  

#BOMCAS #Photographer #Videographer #SherwoodPark #Alberta #Canada #LiveStream

#event #Marketing #SocialMedia #Video #videography

#Photography #photo #videogtapher #videography #Livebroadcast #Concert #Wedding #Weddingphoto

#weddingvideo #weddingphotogyapher #weddingvideo #weddingplanning #weddingmakeup #marketingvideo

#weddingvideographer #Graduation #Funeral #videoproduction #videoediting #ads #advertisment

#videorecording #music #party #partyphoto #partyvideo #musicvideo #church #videocourse #safetytraining #trainingvideo

#Realestate #realestatephoto #realestatevideo #virtual #virtualtour #safety #Edmonton

#canada #toronto #ontario #calgary #sherwoodpark #bc #nature #wildlife #wildlifephoto

 

Shows how an intentional focus on what you want rather than on what you're trying to avoid turns insight into actions and actions into breakthrough results

Provides unique and practical exercises and aids—including an online Seeing Red Cars toolkit

Based on the popular Seeing Red Cards film—currently in use by more than 500 trainers and leaders worldwide

 

Here's the metaphor: You buy your dream car and it happens to be red. Suddenly you see red cars everywhere you look. Why? Because you're focusing on red cars. And as workplace dynamics and change expert Laura Goodrich points out, you get more of whatever you focus on. The problem is in life we unconsciously focus more on what we fear and are trying to avoid than on what we want to have happen. Her positive-outcomes mindset helps you deflect thoughts of what you don’t want and get more of everything you do—for yourself and your organization.

 

BOMCAS LTD www.bomcas.com

Photographer and Videographer Sherwood Park Alberta Canada

  

Record and Live Stream your event today, increase your market share.

•Business Marketing

•Social Media Marketing\management

•Increased Attendance

•Better Marketing Efforts

•New Revenue Opportunities

•Audio Recording

•Video and Photography

•Live stream\broadcast event

•Concert

•Wedding

•Graduation

•Funeral

•Video Recording/Editing

•E-Learning course

•Safety Training course

•Virtual tour

 

Whatever your event is we photograph, record and broadcast live to your desired platform.

 

Edmonton Videographer & Video Production

Sherwood Park Photographer & Video Production

  

#AudioRecording #Edmonton #toronto #london #calgary #stAlbert #canada #Reddeer #fortmcmurray #yeg #Vancouver

#Kitchener #Ontario #Winnipeg #Manitoba #Hamilton #Quebec #Ottawa #BritishColumbia

#Montreal #Camrose #Chestermere #ColdLake #FortSaskatchewan #Saskatchewan #GrandePrairie

#Lacombe #Leduc #Lethbridge #Lloydminster #MedicineHat #RedDeer #SpruceGrove #Wetaskiwin

#NovaScotia #NewBrunswick #Manitoba #PrinceEdwardIsland #NewfoundlandandLabrador

#NorthwestTerritories #Yukon #Nunavut #Victoria #Winnipeg #Fredericton #StJohn's

#Halifax #Charlottetown #Regina #Whitehorse #Iqaluit #Yellowknife #Moncton #Saskatoon #Montreal

#Niagara #Waterloo #Windsor #Sarnia #Kingston #Burlington #Brampton

  

#BOMCAS #Photographer #Videographer #SherwoodPark #Alberta #Canada #LiveStream

#event #Marketing #SocialMedia #Video #videography

#Photography #photo #videogtapher #videography #Livebroadcast #Concert #Wedding #Weddingphoto

#weddingvideo #weddingphotogyapher #weddingvideo #weddingplanning #weddingmakeup #marketingvideo

#weddingvideographer #Graduation #Funeral #videoproduction #videoediting #ads #advertisment

#videorecording #music #party #partyphoto #partyvideo #musicvideo #church #videocourse #safetytraining #trainingvideo

#Realestate #realestatephoto #realestatevideo #virtual #virtualtour #safety #Edmonton

#canada #toronto #ontario #calgary #sherwoodpark #bc #nature #wildlife #wildlifephoto

 

Filming of internal training video for Barclays Bank

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