<h1>The 5 S</h1>
before and after change over times
achieved WITHIN 1 WEEK
The following comments were made after Reduced Effort Changover Kaizen Events. All the principles of 5S are addressed during these events.
“I Can't believe a 42 minute filler change over is now 7 minutes. Simply awesome!”
Tommy Williams, Manager, World Class Manufacturing
Major household cleaning products manufacturer
“Thank you very much for leading the event this week. We had been working on change overs here for quite some time and had already made big reductions. for both groups to get an additional 50% reduction is really amazing. Doug Pulley even made the comment that this was the most productive event he had ever participated in since he joined the company 25 years ago.”
Jamie Owen, Plant Manager
Major household consumer products manufacturer
“I participated on the labeler team, and it was impressive to witness how the process really drove results. Prior to the event downtime took over 700 tasks and 60 minutes to complete. Both of those numbers were cut by 50%. The nice thing is that this is not about working harder and faster to achieve a shorter downtime, but rather it is about eliminating wasted efforts. Since the operators were taking charge in figuring out the improved way, you could plainly see their ownership. Very impressive process and I was grateful to have been a part of it. I firmly believe that this is valuable training and that everyone should go through.”
Reyes Fragosa, Chemical Engineer
Major automotive products company
“This event was a very positive experience at our plant. As a result we saw significant reduction and simplification in change over, plus and increase in operator ownership.”
Rick Vannan, Plant Manager
Major household consumer products company
“Awesome loss elimination process and results!”
Tim Bailey, VP Product Supply
Major household cleaning products manufacturer
“This Reduced Effort Changeover process absolutely develops standard best practice work.”
Mike Standley, Technical Manager
Major beverage company
“It has been one month since our Reduced Effort Changeover event and we had another ‘best ever’ again this week. Our big ‘impossible’ goal was smashed again this week. We have had ‘best ever’ times 4 times in the past week. The Reduced Effort process works and the product output is showing the fruits of this work. The teams are looking forward to their reward breakfast.”
Rob Martz, Process Engineer
Major Ice cream manufacturer
“For our plant, the biggest impact from the Reduced Effort Changeover (REC) process was beginning to see a change in culture where technicians are now engaged in the process and feel some ownership for making the changeover as effortless as possible. Prior to REC they felt like the changeover was the best it could be and if it were to be changed, it was Management’s job to change it. Now they see they have the ability to make changes.”
===Danielle Hess, Operations Manager, Major extruder of plastics.........
Update: "I just wanted to give you a quick update on our REC progress. The changeover we did this afternoon was 40 minutes (during the REC Event the time was reduced from 347 minutes to 108 minutes). I just wanted to let you know we continue to make progress!!"
===Danielle Hess, Operations Manager, Major extruder of plastics
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Phone: 1-209-814-9198 Email: ron@reducedeffort.com