Issue link: https://iconnect007.uberflip.com/i/1456062
MARCH 2022 I SMT007 MAGAZINE 97 "As you can see, we organized the shop floor using 5S and addressing 8 Muda issues. e rework stations all have shadow graphs for the tools, and we have encouraged the staff to keep them neat. We have been impressed with the many helpful suggestions the workers have made to help us achieve an effective work- flow," John said. "Everyone chipped in and worked with a few plumbers, carpenters, and electricians to update the restrooms, the break rooms, and the basic structure of the two buildings. I think all of us did a lot of painting," Maggie added with a chuckle. "We have had several meetings to explain the importance of uptime, quality, and productiv- ity in general," she continued. "We have daily Pareto charts posted to show yield fallout, and graphs to demonstrate important productivity metrics. We have made a considerable effort to help us understand what makes Ivy Benson productive with quality products." As they walked, John told Ned, "We are training the operators to understand how the machines work, and how to operate them most effectively. All operators can be cross- trained on as many machines as they like. We have been really impressed by how enthusias- tic the staff has been with these opportunities. On a side note, the solder paste being used was inexpensive, but it had response- to-pause and yield issues, so we replaced it with a more expensive, but better one." e one-way chatting continued as they walked to the breakroom. Ned looked around at the new vend- ing machines. His eyes wandered over the low prices. He looked at the two computers. He looked angry. "We have installed Wi-Fi in the facility for the workers to use dur- ing their breaks," Maggie proudly stated. ey then headed to the rest- rooms, ensuring they were empty first. Ned glared at the attractive new fixtures and the overall bright, cheery appearance. Neither Maggie nor John knew if he noticed that the bad odor was gone. As it was obvious that they were finished, Ned began to speak. "You two have ruined my masterpiece! I was determined to deliver to my customers the lowest possible price, and I did it by reducing my costs. You two have gone crazy by spending all this money to make the place look fancy and by coddling the workers. ey will just take advantage of you." As his face turned red, he continued, "Sub- sidized vending machines and Wi-Fi? Are you da? e workers will be in the break room all day goofing off. And educating them? What a joke! ese aren't the kind of people that you educate. When you do, they will just leave for other companies. "I have a mind to start a new business to take care of my customers since you two have aban- doned them," he finished with rage in his voice. ere was silence for a moment, then John responded, "Our colleague, Frank Emory, has performed a cost and profit analysis of the busi- ness when you owned it vs. aer we took over. By improving uptime, productivity, and qual- ity, we have reduced our manufacturing costs considerably and have passed some of these savings on to our, not your, customers." Figure 2: The renovated breakroom was appreciated by the team at Ivy Benson.