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Ventana USA

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Ventana USA

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    1. Ventana USA Implementation of LEAN and 5 S

    2. Ventana Celebrates 20 Years Ventana USA is an expert in the art and engineering of vinyl profile bending. Our experience with hundreds of various extrusions has made us the leader in the market.Ventana USA is an expert in the art and engineering of vinyl profile bending. Our experience with hundreds of various extrusions has made us the leader in the market.

    3. Specialty Shapes Architectural Windows Custom Bending and Fabricating of Shapes for Vinyl Window Manufacturers Custom Bending of Trim for Interior and Exterior Applications Garden Windows As you saw earlier Building 1 solely manufactures our Shaped WindowsAs you saw earlier Building 1 solely manufactures our Shaped Windows

    4. Fence and Railing - FDR Fence Bending,Welding, and Routing Bending of Vinyl Components to compliment existing Fence Sections Routing of Bent Sections to match existing Picket configurations Railing Bending and Routing Bending of Vinyl Railing to match contours of Decks, Stairs, and Railing Applications Routing of Bent Sections to match desired picket or glass specifications

    6. The Beginning of Change Reasoning behind LEAN and 5S Fence and Railing an expensive hobby Uncontrolled Hours Excessive OT Unorganized Work Flow Bottlenecks delaying production No Quality Control Lack of Information Bending Times Unknown Routing Times Unknown Average Hours worked a month before 1600 (6 guys) Lack of Information made scheduling orders and spikes in business a nightmareAverage Hours worked a month before 1600 (6 guys) Lack of Information made scheduling orders and spikes in business a nightmare

    7. Where To Start Identify what Changes Need to Occur Capture the Low Hanging Fruit 1st Where are our MAJOR Sources of Waste Motion people, material, equipment Repairs reworks Delays Set-Up / Bottlenecks / Lag Time Production Methods

    8. Workers Input and Buy In Brien Palmer & Doug Rosensteel Hold Weekly Meetings 1st Develop Project Plan based on Ideas 2nd Involve all Workers into Meetings General Training of Principles of LEAN and 5S Work Toward a Common Goal Blue Sky Exercise Redesign Entire Work Flow

    10. Free Flowing Ideas Based on Right Things Right Place Right Time New Work Flow Change of Entire Process Material Handling Inventory Storage Tool Changing Methods Router Set-Up Work Stations with Proper Equipment Tool Storage Areas Mats & Templates Develop Standards with Bends and Jobs Standard Operating Procedures

    11. Implementing Change Planning: Strategize each Change Moving and Rewiring: Organized list of when the Move or Rewiring would occur Painting: Starting Fresh new look

    12. Employee Designed Work Flow

    13. 5 S Sort: Redesigned Overall Flow Created Work Stations including Tools Straighten: Organized Areas for Templates and Mats Developed a Work Flow per Station Consolidated Materials to more Accessible Areas Shine: Established Cleaning Procedures & Schedules Developed Cleanliness Levels Standardize: Developed a Go No Go Gauge Pictures of Procedures and Quality Expectations Ordered Individual Tools based on Work Stations Cut Off Rack with Fill Level & Size Gauge Sustain: Management Consistency and Adherence to 5 S Weekly Meetings for Continued Employee Participation Developed a 5 S Audit - Scorecard

    14. Benefits of LEAN and 5 S Employees Employee Satisfaction Input and Control of THEIR Workstation Implementation of 4 (10s) Flexible Schedule Promotes Team Work Pride & Increased Morale

    15. Benefits of LEAN and 5 S Ventana 91% Increase in Net Profit $30.- Increase in Revenue per Hr worked After Material 48% Fewer Hours worked 1580 per month to 840 per month Same Sales & 1 Fewer Employee Scheduling Proper Management of Orders and Lead Times Lead Times Down From 2 weeks to between 2 and 7 Days Knowledge of Work Times Costing Method Profit Analysis of each Job Material Usage Decreased Costs Glycerin Usage from 6.1% of Sales to 1.1% of Sales

    16. Lessons Implementing LEAN and 5 S Employee Buy In and Participation is KEY Start with the Low Hanging Fruit Training and Understanding of How LEAN and 5 S equate to YOUR Business is Vital Change and Manipulate each to Fit your Production

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