The Mount Pleasant shop went through quite a transformation the week of April 11, 2016. IPI management, training and shop staff, along with John Magnussen from Pella Windows, all came together to Sort, Set In Order, Shine and Standardize the shop! What a difference!
The goals for this event:
- To provide a safer more efficient workplace for everyone.
- To provide training in Lean to develop skills for everyone.
- To be a better supplier for our customers.
The first day was Sort; the shop disposed of several truckloads of excess materials and equipment that were taking up valuable space in the shop. This freed up 400 square feet of space that can now put to better use. Inventory levels to maintain were also established.
Next came Set in Order on day two; this began with re-arranging and figuring out the best place for everything. Floors were marked so that everyone would know where to place the raw materials, where the walkways were, and so on. The incarcerated men joined together to decide where things would work best to save time and steps, produce a better work flow, and reduce movement of materials. Other changed included painting the fire extinguisher columns red, marking locations of fire alarm pulls and electrical panel clearance areas, and relocating the flammable cabinets per OSHA standards.
After the Sort and Set in Order, it was time to Shine; the shop was swept and dusted and mopped and scrubbed until the shop was, well, shining!
On day four the Standardizing of everything began which is still a work in progress. In the weeks following the event, the shop has installed better lighting, pole mounted fans and hose reels to free up floor space and reduce tripping hazards, and location signs all around the shop. The incarcerated individuals are busy trying to complete all the tasks.
The hardest step of 5S is Sustain as old habits die hard. However, everyone is happy with the new setup of the shop and the improved working conditions, and that will help to sustain all the changes that have been made.
Many thanks to everyone involved in improving the Mount Pleasant shop. Both staff and inmates were pleased at the end of the week when they could look around the shop and know that their work environment is now set up to make their jobs safer and more productive.