PRT Oregon – Our Lean Journey
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Transcript of PRT Oregon – Our Lean Journey
PRT Oregon – Our Lean Journey
Mark MontvilleNursery Manager, PRT Oregon
Far West ShowAugust 27, 2011
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Presentation Overview
PRT – Who we are and what we do.Our lean management work prior to
OAN’s Lean Pilot Program.Our participation in OAN’s Lean
Pilot Program.
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PRT – Who We Are
PACIFIC
REGENERATION
TECHNOLOGIESForest seedling company.
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PRT Locations
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PRT – What We Do
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PRT Oregon Continuous Improvement
Continuous Improvement Meetings Brainstorming session – identify
improvement opportunities for a given operation.
Include all participants in operation.Done in a “classroom” setting after
operation was complete.
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PRT Oregon Continuous Improvement
Continuous Improvement Meetings Select which opportunities to evaluate
further. Determine improvement actions.Assign responsible parties to
implement actions.Include completion deadline dates.
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PRT Oregon Continuous Improvement
Training Session.
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PRT Oregon and OAN’s Lean Pilot
Continuous Improvement Event (Kaizen)
Goal - reduce time wasted during machine change-overs.
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Seedling Lifting Operation
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Seedling Lifting Operation
Automatic pin extractor.
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Seedling Lifting Operation
Automatic pin extractor.
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Seedling Lifting Operation
Machine Change-over.
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Seedling Lifting Operation
Machine Change-over – Improvement Opportunities. While pins are being changed, 14 workers
are no longer packaging seedlings. It takes 8 minutes to change-over
equipment. We package 10 seedlings per worker
minute. Therefore, we lose the opportunity to
package 1,120 seedlings during each change-over.
Every 4 minutes of idle time = nearly 1 worker hour.
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Seedling Lifting Operation
Machine Change-over – Improvement opportunities.Replace air wrench.Mark pins so installer always knows
which side is the top of the pins.Add a stop mechanism to pins that will
allow change-over person to easily position them on the lower mounting peg.
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Seedling Lifting Operation
Machine Change-over – Improvement opportunities.Add visual marks to show where to
position block carraige for each block depth.
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Seedling Lifting Operation
Empty Container Handling - Problem
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Seedling Lifting Operation
Empty Container Handling - Problem
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Seedling Lifting Operation
Empty Container Handling – Problem.
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OAN Lean Pilot Program
Empty Container Handling – Problem.
Block Loader/Stacker worker made about 100 trips per shift up and down steps.
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OAN Lean Pilot Program
After considering all sorts of alternate routes to convey empty blocks, we
learned the answer was right
in front of us.
Empty Container Handling – Problem.
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Seedling Lifting Operation
Empty Container Handling – Lean Approach to Solution
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Seedling Lifting Operation
Empty Container Handling – Lean Approach to Solution
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Seedling Lifting Operation
Empty Container Handling – Solution Trials
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Seedling Lifting Operation
Empty Container Handling – Solution Trials
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Seedling Lifting Operation
Empty Container Handling – Implemented Solution
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Benefits of Participation
Very helpful in getting us past the “classroom phase” and to the doing phase.
Introduced us to the concept of “Trystorming”. People too willing to get bogged down in speculating outcomes.
Reinforced the Plan Do Check Act cycle.Reinforced - including the people doing the
work and going to where the work is being done.
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Benefits of Participation
Allows people unfamiliar with your operation to see it and put forth suggestions based on their experience. Sometimes we can’t see the forest through the trees.
Helps you identify waste. There are many types of waste. Cost savings realized from reducing waste add up quickly.
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Thank you.