Introductory LEAN training has been completed for all associates in Phoenix. Training covered an overview of LEAN, an introduction to 5S, and an introduction to visual controls. Traditional Powerpoint slides were augmented with a DVD on making toast (5S Training) and "house drawing" exercise aimed at demonstrating the importance of using visual controls. Associates were generally attentive during the presentation, and seemed to enjoy the DVD and the drawing exercise. The images below show some of the activities during training.
Operations Director Rob Mays presents the fundamentals of 5S to a group of receiving associates. Notice that none of the associates are sleeping! A positive sign!
A group of associates from production and delivery are working on the 5S word search exercise. This exercise is comprised of a series of six word search puzzles and demonstrates the power of what 5S can do when applied and sustained. 5S principles work whether applied to a word search, and simulation, or real life distribution work.
Associates are drawing houses as part of an exercise designed to demonstrate the power of using visual controls to achieve a standard outcome. A picture is worth a thousand words!
As expected, associates adapted to the training in different ways. Few showed outward resistance, but comments sometimes betrayed their skeptical thoughts. A few associates were quickly enthusiastic supporters of these newly introduced principles, they see the power! Most associates are taking a wait and see approach ... if they begin to see value, they will become supportive of our LEAN effort.
Culture is the biggest obstacle in Phoenix. Many long-term associates want to continue to work in the same processes as in the past. For some, change is a challenge in itself. While our associates are changing at different speeds from one another, they are changing. Little by little, people are learning to see things differently, through new eyes. Ideas are beginning to bubble up from the front line people. As we execute those good ideas, more will come forward as associates develop the knowledge and confidence that they can indeed make a difference in their work place and the performance of their team!
We have created our first Single Point Lesson in the Phoenix CFC. This simple document provides instructions for our check-pack associates regarding how to apply air pillows as dunnage for outbound cartons. It is designed to be used by experienced associates, as well as people "filling in" at that work station for a short time. After printing the sheet in color, we added a cardboard backing and laminated the page. It has been mounted in the work station for all to see as they work with air pillows.
