General CI Projects
Central Plant HVAC Office 5S Project – April 2015
- After experiencing the improvements made by applying the LEAN tool 5S in several equipment/part storage areas at Central Plant, Diane Zekind decided to apply this LEAN tool to the HVAC office in the Central Plant. Before implementing LEAN 5S, files were hard to find due to being misplaced on a desk or not having a designated place. After 5S, extra copies of files and other unneeded items were disposed of and needed materials were organized and placed in file drawers. Visual standards were created to show how the office space should be maintained.
“Office 5S”: Student Crafts on the Square – March 2015
- The “Office 5S” performed at the Student Crafts on the Square (SCOTS) was done with Steve Davis-Rosenbaum by Logan Gardner, Continuous Improvement Projects Assistant. The “Office 5S” was implemented primarily to organize Steve’s workspace while giving him a standard workflow to follow. We applied one of the LEAN tools, 5s which stands for Sort, Set-in-order, Shine, Standardize, and Sustain.
The process began with the first S, sort. A red tag area was used to remove items that were not located in the correct area or no longer had any use. Once the sorting process was complete, the next S was executed, set-in-order. The office was organized and a space for everything was created. Then, using the organizational skills for email in The Hamster Revolution, by Mike Song, Vicki Halsey, & Tim Burress, Steve created a system that organized his email in such a way that emails from certain people were given a high priority while others were given a lower priority. After organizing his email, we evaluated his workflow. This included how Steve handled work, what priorities he set, what work he accepted, and how he scheduled his work. In addition to using a WIP board, we created queue folders for the major jobs Steve would be working; one for the craft education for outreach program and the other for the SCOTS. This change allowed Steve to track his work better while setting priorities to that work allowing him to be more efficient.
Once we had Steve’s office organized and his workflow set-in-order, we began the third S, shine. The office was cleaned, removing any dust and dirt build-up for a better looking workplace that would allow him to take pride in its appearance. After completing the shine step, we then used the fourth S, standardize. To create a standard, we went through many revisions of how the office was arranged before Steve found a standard that met his needs. Each revision usually involved only small changes such as folder placement, power strip placement, or desk arrangement. Finally, we took pictures to create and display a visual standard and an audit report. Both are used by Steve and his colleagues at the end of work day. These actions were the basis for completing the never ending fifth S, sustaining the first four Ss.
Wood Craft Standard Work Project – February 26, 2015
- The Woodcraft area of Student Crafts recently applied a LEAN technique to prevent defects from occurring with the Skittles Games. This was accomplished through the use of standard work procedures. There had been some confusion about which of the pieces were assembled together and how they were placed in the jig. Therefore, standard work instructions were placed in the area. Above the instructions is a diagram of the layout of the pieces on the table. This creates a visual reminder of which pieces should be assembled together. The instructions themselves reiterates which of the pieces should be assembled together and how they should be assembled.
Wood Craft Point of Use Project- February 11, 2015
- The Woodcraft area of Student Crafts recently applied a LEAN technique to maintain enough parts to make a batch of Skittles Games. They accomplished this through the implementation of Point of Use Storage. The students would try to make Skittles Games, but they would always have to sand parts before they could make them. Point of Use Storage is the holding of raw materials in the place at which they are used. Woodcraft applied this by using a shelf to store the sanded parts and one right next to it to store the parts that were not sanded. The sanded parts were placed on the shelf next to where the students complete the first steps in assembly. The parts that were not sanded were placed on the shelf behind the sanding tables. Then the parts were organized on the shelves so that the parts that were assembled at the same time were grouped together. Finally, the inventory levels were marked on each shelf with red and green tape for the minimum and maximum amounts of the parts, and their placement was marked with white tape and labeled.
College Store Project – May 6, 2014
- The Berea College Store recently applied a LEAN technique to improve situational awareness for its labor students. Nate Daniels attended the one day class “Disciplines of Speed” and as a result implemented a WIP board in order to keep his students informed about what tasks they have been assigned each day. The benefit of this is that the students can check the board when they come in and instantly know what to start working on for the day. Nate Daniels also implemented a separate WIP board to manage his projects.
Scots Project – April 15, 2014
- An interdepartmental team from the Pinnacle and Student Crafts on the Square Gallery cooperated to come up with an innovative lean-green project that has hard savings. The students at SCOTS Gallery were looking for ways to lean-green their processes and came up with the idea of using newspaper to wrap purchased merchandize replacing the tissue paper that they normally use. Here’s where their across campus friends at Berea College’s newspaper, The Pinnacle, came up with their own contribution to this lean-green project. They had in the past accumulated obsolete newspapers that would go to the recyclers but by using them one more time before being recycled (called upcycling) they solved SCOTS Gallery sourcing of usable newspaper. In addition to the saving of the cost of the tissue paper, there is the possibility that this customer will get a secondary exposure to Berea’s commitments when they unwrap their purchase and read an article from the Pinnacle.
Alumni and College Relations Project – February 28, 2014
- A team in Alumni and College Relations recently applied a LEAN technique in their department. Troy Price attended the one day class “Disciplines of Speed” where he learned about ways to improve situational awareness and management of open projects by using a WIP board. The team composed of Nancy Gow, Molly Smith, Danna Derr, and Troy Price worked to tailor a basic WIP board to their particular needs. You can see on their board that they track their queued, work in process, and completed projects. Sometimes when a project does not have resources it will be set aside with the possibility that it is forgotten. One of the benefits that they have found is that it keeps tasks visible preventing them from languishing. Now when resources are available they can select one of these older project to address. Another benefit is the ability for student workers to move their finished projects to the completed area of the board and select the next project without the need for direct supervision. Stop by and discuss with the team how they use the board. They would be more than happy to share their experiences and help you apply WIP boards in your area.
CELTS Activity Boards Project – February 15, 2014
- The Center for Excellence in Learning through Service (CELTS) recently applied several LEAN techniques. Heather Schill attended the one day class “Disciplines of Speed” and as a result implemented several ways to improve the use of emails. She was so successful that she no longer has to catch up on emails at night and spends more time with her family. Likewise, she and the students in CELTS began using activity boards in order to stay informed about what tasks they have been assigned each day. The benefit of this is that the students can check the boards when they come in and instantly know what to start working on for the day.