STANDARD REGISTER5S/LEAN Journey

Start Date: 09/14/2012

5S Fed Ex Department

Before & After

5S Kitting Department

Before & After

5S Kitting Department

Before & After

5S Bindery Department

Before & After

5S Offset Department

Before & After

5S Offset Department

Before & After

5S Binder Storage

Before & After

5S Offset Department

Before & After

5S Die Cutting Department

Before & After

5S Bindery Department

Before & After

5S Bindery Department

Before & After

5S The OCE Parts Room

Before & After

The employees in the POD Shipping department had an idea for a cleaner/better workflow and came up with a design of how it could flow more efficiently. WOW now

that’s a good flow.

5S POD Shipping Department

Before & After (results of the drawing)

Before it was sloppy, inefficient, and unsafe. You see what a $1.50 part can do. Lean doesn't have to cost a lot to be effective.

Before & After

POD Shipping WOW

LEAN is contagious, a mystery person cleaned up this area without being told, I’m impressed

LEAN is contagious:

QA Quarantine Cage:

We created a Quarantine SOP to gather a data base for internal and external non-conformances now we will be

able to look at, track and attack our internal issues.

Lean Initiatives:

Lean Initiatives:

Every step in Lean is considered Waste

The postage machine in the POD So we moved it to the KittingShipping area is primarily used in Department.the Kitting Department.

Lean means visual Aids

Before & After

Lean is Green:

We Added a recycling bin in the POD department. Not only did we reduce trash cost we turned it green.

LEAN Thinking:

Hard at work with LEAN, your never finished improving.

Lean Initiatives: TD Bank/Capital One work cell evolved to an efficient work center that’s ready

for any challenge

Lean/5S Initiatives:

LEAN Initiative

Cross training is a key element in the Lean process.

Lean initiatives

Before & After

LEAN Initiative

With Lean all processes need to be standardized and documented this is just the beginning.

LEAN Initiative

Our kitting tool kits all go in a tote for easy access.

LEAN InitiativeLean can make you rich Paul Maddesi won a $25 gift card

for his contribution to the PI Corporate program.

With Lean your never done improving the process.

We started with a binder for our 5S checklist using a single page for each day and it evolved to a flip chart which saves paper and is visual for all to see.

BEFORE AFTER

LEAN Initiative

Westampton did their first official 5S Audit January 22nd and scored an 82.6% not bad for our first audit.

Flawless Execution Day

Sometimes you need to get the POM POMS out to get people excited about an important day or event.

With 5S your never done cleaning.

BEFORE AFTER

With 5S your never done cleaning.

BEFORE AFTER

With 5S everything has a place .

Employees had no place to put their coat or other personal items which was hurting our 5S scores,

so we got Lockers.

BEFORE AFTER

We used to use cut sheets of white paper to stuff kitting boxes, we now use brown Kraft paper which is half the cost and must more

efficient.

BEFORE AFTER

Lean/5S Initiatives:

We are always ready for an audit or surprise guests when you 5S.

Bindery Kitting

We are always ready for an audit or surprise guests when you 5S.

Star Shipping POD

Our next step in our Lean Journey is to Value Stream map our process.

We have only just begun, this process will take us weeks to analyze and then build a new map.

We created a Lean Roadmap, we are going to be busy in 2013!

We now post our monthly ecars and put our external ones on a board for all to see.

Monthly external/internal Ecars External Ecar Samples

We did a record amount of books for one customer in a single day and the department

Lead wanted to thank all.

This is what happens when you have a good 5S/Lean program the PI ideas from employees come pouring out. We lead all centers in Q1.

We had to run many products through the I-Gen twice to put 2 scores into the product costing us valuable press

time, we researched and bought a scoring/perfing unit for under $1000.

New Deloitte SOP tells us we must keep all orders separated, so we went out and purchased some low cost

plastic bins for less then $200.

5S begins in the office!

Emergency Evacuation Binders are at all exits, each binder has company roll call, a copy of the evacuation plan and important phone numbers.

Tornado Shelter is posted in plant

Outside the tornado shelter area and in the Supervisors office is a weather radio and flashlight

that crank to sustain power, the radio will also charge your cell phone.

The Supervisor/prepress room has been 5Sed, WOW!!!

We did our first plant wide QA Audit in June and finished with a respectful score of 84.5%

Last year at this time we had 116 external ecars this year we have 38 wow what a difference a

year makes.

Since practicing JIT this is all the excess inventory we carry, we rank number one

companywide in inventory turns and that means cash flow.

This is what I walk into every morning in M30 Kitting that’s 5S to the max..

TO BE CONTINUED…