{"id":68257,"date":"2025-10-17T16:05:47","date_gmt":"2025-10-17T20:05:47","guid":{"rendered":"https:\/\/www.flexpipeinc.com\/?page_id=68257"},"modified":"2025-10-17T16:05:52","modified_gmt":"2025-10-17T20:05:52","slug":"corrugated-packaging-material-handling","status":"publish","type":"page","link":"https:\/\/www.flexpipeinc.com\/ca_en\/corrugated-packaging-material-handling\/","title":{"rendered":"Discover the benefits of Lean Manufacturing in the corrugated and packaging industries"},"content":{"rendered":"\n<div class=\"wp-block-cover\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"350\" class=\"wp-block-cover__image-background wp-image-24201 size-full\" alt=\"\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c.jpg\" data-object-fit=\"cover\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-768x330.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-375x161.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-36x15.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-48x21.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><span aria-hidden=\"true\" class=\"wp-block-cover__background has-background-dim-100 has-background-dim wp-block-cover__gradient-background has-background-gradient\" style=\"background:linear-gradient(70deg,rgb(0,0,0) 0%,rgba(0,0,0,0.38) 98%)\"><\/span><div class=\"wp-block-cover__inner-container is-layout-flow wp-block-cover-is-layout-flow\">\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h1 class=\"wp-block-heading\"><strong><strong>Discover the benefits of Lean Manufacturing in the corrugated and packaging industries<\/strong><\/strong><\/h1>\n\n\n\n<p>The packaging and corrugated cardboard industries need to work harder to meet growing industry demand.&nbsp;<strong>The significant rise in e-commerce and meal delivery services is forcing players to rethink the way they work.<\/strong>&nbsp;An interview with Leslie Pickering, consultant and co-owner of Quadrant5, details the work method and process improvements required to increase the productivity of manufacturers in the paper and cardboard industry.<\/p>\n\n\n\n<p><strong>Leslie\u2019s approach focuses on the benefits of lean manufacturing<\/strong>. He presents some main wastes in manufacturing, 12 lean successes following the implementation of the proposed system, the paradigm related to resistance to change, as well as the handling system fostering employee creativity.<\/p>\n<\/div><\/div>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-group is-style-container typography\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<div class=\"wp-block-group has-background\" style=\"background-color:#eaeaea\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\"><div class=\"root-eb-toc-0nol1 wp-block-essential-blocks-table-of-contents\"><div class=\"eb-parent-wrapper eb-parent-eb-toc-0nol1 \"><div class=\"eb-toc-container eb-toc-0nol1  eb-toc-is-not-sticky eb-toc-collapsible eb-toc-initially-collapsed eb-toc-scrollToTop style-1 list-style-none\" data-scroll-top=\"false\" data-scroll-top-icon=\"fas fa-angle-up\" data-collapsible=\"true\" data-sticky-hide-mobile=\"false\" data-sticky=\"false\" data-scroll-target=\"scroll_to_toc\" data-copy-link=\"false\" data-editor-type=\"\" data-hide-desktop=\"false\" data-hide-tab=\"false\" data-hide-mobile=\"false\" data-itemCollapsed=\"false\" data-highlight-scroll=\"false\"><div class=\"eb-toc-header\"><h2 class=\"eb-toc-title\">Table of Contents<\/h2><\/div><div class=\"eb-toc-wrapper hide-content\" data-headers=\"[{&quot;level&quot;:2,&quot;content&quot;:&quot;About Leslie Pickering&quot;,&quot;text&quot;:&quot;About Leslie Pickering&quot;,&quot;link&quot;:&quot;about-leslie-pickering&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;The 5 trends changing the industry&quot;,&quot;text&quot;:&quot;The 5 trends changing the industry&quot;,&quot;link&quot;:&quot;the-5-trends-changing-the-industry&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;Further consolidation?&quot;,&quot;text&quot;:&quot;Further consolidation?&quot;,&quot;link&quot;:&quot;further-consolidation&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;A new major player in the USA&quot;,&quot;text&quot;:&quot;A new major player in the USA&quot;,&quot;link&quot;:&quot;a-new-major-player-in-the-usa&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;INCREASE PRODUCTIVITY WITH THE LEAN PHILOSOPHY&quot;,&quot;text&quot;:&quot;INCREASE PRODUCTIVITY WITH THE LEAN PHILOSOPHY&quot;,&quot;link&quot;:&quot;increase-productivity-with-the-lean-philosophy&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;Why go to such an effort to become Lean?&quot;,&quot;text&quot;:&quot;Why go to such an effort to become Lean?&quot;,&quot;link&quot;:&quot;why-go-to-such-an-effort-to-become-lean&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;Lean manufacturing\\u2019s presence in the industry at a glance&quot;,&quot;text&quot;:&quot;Lean manufacturing\\u2019s presence in the industry at a glance&quot;,&quot;link&quot;:&quot;lean-manufacturings-presence-in-the-industry-at-a-glance&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;Upper management in the Lean integration process&quot;,&quot;text&quot;:&quot;Upper management in the Lean integration process&quot;,&quot;link&quot;:&quot;upper-management-in-the-lean-integration-process&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;8 manufacturing wastes&quot;,&quot;text&quot;:&quot;8 manufacturing wastes&quot;,&quot;link&quot;:&quot;8-manufacturing-wastes&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;ROLE OF THE WATER SPIDER IN A LEAN STRUCTURE&quot;,&quot;text&quot;:&quot;ROLE OF THE WATER SPIDER IN A LEAN STRUCTURE&quot;,&quot;link&quot;:&quot;role-of-the-water-spider-in-a-lean-structure&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;The 12 achievements of a lean factory after a great a lean journey&quot;,&quot;text&quot;:&quot;The 12 achievements of a lean factory after a great a lean journey&quot;,&quot;link&quot;:&quot;the-12-achievements-of-a-lean-factory-after-a-great-a-lean-journey&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;1 - A pull system is used for the production system&quot;,&quot;text&quot;:&quot;1 - A pull system is used for the production system&quot;,&quot;link&quot;:&quot;1-a-pull-system-is-used-for-the-production-system&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;2 - Standardized work in all work cells&quot;,&quot;text&quot;:&quot;2 - Standardized work in all work cells&quot;,&quot;link&quot;:&quot;2-standardized-work-in-all-work-cells&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;3 - Changeover time is limited to 10 minutes&quot;,&quot;text&quot;:&quot;3 - Changeover time is limited to 10 minutes&quot;,&quot;link&quot;:&quot;3-changeover-time-is-limited-to-10-minutes&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;4 - One-piece flow is in place throughout the plant&quot;,&quot;text&quot;:&quot;4 - One-piece flow is in place throughout the plant&quot;,&quot;link&quot;:&quot;4-one-piece-flow-is-in-place-throughout-the-plant&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;5 - Poka-yoke helps to make work easier and improves quality&quot;,&quot;text&quot;:&quot;5 - Poka-yoke helps to make work easier and improves quality&quot;,&quot;link&quot;:&quot;5-poka-yoke-helps-to-make-work-easier-and-improves-quality&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;6 - Visual control to help team leaders&quot;,&quot;text&quot;:&quot;6 - Visual control to help team leaders&quot;,&quot;link&quot;:&quot;6-visual-control-to-help-team-leaders&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;7 - A sustainable 5S program&quot;,&quot;text&quot;:&quot;7 - A sustainable 5S program&quot;,&quot;link&quot;:&quot;7-a-sustainable-5s-program&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;8 - Inventory management is done visually&quot;,&quot;text&quot;:&quot;8 - Inventory management is done visually&quot;,&quot;link&quot;:&quot;8-inventory-management-is-done-visually&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;9 - There is a company-wide kaizen program&quot;,&quot;text&quot;:&quot;9 - There is a company-wide kaizen program&quot;,&quot;link&quot;:&quot;9-there-is-a-company-wide-kaizen-program&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;10 - Training programs are ahead of the competition\\u2019s&quot;,&quot;text&quot;:&quot;10 - Training programs are ahead of the competition\\u2019s&quot;,&quot;link&quot;:&quot;10-training-programs-are-ahead-of-the-competitions&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;11 - A preventive maintenance program reduces downtime&quot;,&quot;text&quot;:&quot;11 - A preventive maintenance program reduces downtime&quot;,&quot;link&quot;:&quot;11-a-preventive-maintenance-program-reduces-downtime&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;12 - It\\u2019s an accident-free workplace&quot;,&quot;text&quot;:&quot;12 - It\\u2019s an accident-free workplace&quot;,&quot;link&quot;:&quot;12-its-an-accident-free-workplace&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;Change resistance is inevitable&quot;,&quot;text&quot;:&quot;Change resistance is inevitable&quot;,&quot;link&quot;:&quot;change-resistance-is-inevitable&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;10 TIPS TO REDUCE CHANGE RESISTANCE&quot;,&quot;text&quot;:&quot;10 TIPS TO REDUCE CHANGE RESISTANCE&quot;,&quot;link&quot;:&quot;10-tips-to-reduce-change-resistance&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;Material handling system part of a lean manufacturing journey&quot;,&quot;text&quot;:&quot;Material handling system part of a lean manufacturing journey&quot;,&quot;link&quot;:&quot;material-handling-system-part-of-a-lean-manufacturing-journey&quot;},{&quot;level&quot;:3,&quot;content&quot;:&quot;Flexpipe tube and joint modular structures examples&quot;,&quot;text&quot;:&quot;Flexpipe tube and joint modular structures examples&quot;,&quot;link&quot;:&quot;flexpipe-tube-and-joint-modular-structures-examples&quot;},{&quot;level&quot;:2,&quot;content&quot;:&quot;Key takeaways&quot;,&quot;text&quot;:&quot;Key takeaways&quot;,&quot;link&quot;:&quot;key-takeaways&quot;}]\" data-visible=\"[false,true,true,true,true,true]\" data-delete-headers=\"[{&quot;label&quot;:&quot;About Leslie Pickering&quot;,&quot;value&quot;:&quot;about-leslie-pickering&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;The 5 trends changing the industry&quot;,&quot;value&quot;:&quot;the-5-trends-changing-the-industry&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Further consolidation?&quot;,&quot;value&quot;:&quot;further-consolidation&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;A new major player in the USA&quot;,&quot;value&quot;:&quot;a-new-major-player-in-the-usa&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;INCREASE PRODUCTIVITY WITH THE LEAN PHILOSOPHY&quot;,&quot;value&quot;:&quot;increase-productivity-with-the-lean-philosophy&quot;,&quot;isDelete&quot;:true},{&quot;label&quot;:&quot;Why go to such an effort to become Lean?&quot;,&quot;value&quot;:&quot;why-go-to-such-an-effort-to-become-lean&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Lean manufacturing\\u2019s presence in the industry at a glance&quot;,&quot;value&quot;:&quot;lean-manufacturings-presence-in-the-industry-at-a-glance&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Upper management in the Lean integration process&quot;,&quot;value&quot;:&quot;upper-management-in-the-lean-integration-process&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;8 manufacturing wastes&quot;,&quot;value&quot;:&quot;8-manufacturing-wastes&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;ROLE OF THE WATER SPIDER IN A LEAN STRUCTURE&quot;,&quot;value&quot;:&quot;role-of-the-water-spider-in-a-lean-structure&quot;,&quot;isDelete&quot;:true},{&quot;label&quot;:&quot;The 12 achievements of a lean factory after a great a lean journey&quot;,&quot;value&quot;:&quot;the-12-achievements-of-a-lean-factory-after-a-great-a-lean-journey&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;1 - A pull system is used for the production system&quot;,&quot;value&quot;:&quot;1-a-pull-system-is-used-for-the-production-system&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;2 - Standardized work in all work cells&quot;,&quot;value&quot;:&quot;2-standardized-work-in-all-work-cells&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;3 - Changeover time is limited to 10 minutes&quot;,&quot;value&quot;:&quot;3-changeover-time-is-limited-to-10-minutes&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;4 - One-piece flow is in place throughout the plant&quot;,&quot;value&quot;:&quot;4-one-piece-flow-is-in-place-throughout-the-plant&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;5 - Poka-yoke helps to make work easier and improves quality&quot;,&quot;value&quot;:&quot;5-poka-yoke-helps-to-make-work-easier-and-improves-quality&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;6 - Visual control to help team leaders&quot;,&quot;value&quot;:&quot;6-visual-control-to-help-team-leaders&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;7 - A sustainable 5S program&quot;,&quot;value&quot;:&quot;7-a-sustainable-5s-program&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;8 - Inventory management is done visually&quot;,&quot;value&quot;:&quot;8-inventory-management-is-done-visually&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;9 - There is a company-wide kaizen program&quot;,&quot;value&quot;:&quot;9-there-is-a-company-wide-kaizen-program&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;10 - Training programs are ahead of the competition\\u2019s&quot;,&quot;value&quot;:&quot;10-training-programs-are-ahead-of-the-competitions&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;11 - A preventive maintenance program reduces downtime&quot;,&quot;value&quot;:&quot;11-a-preventive-maintenance-program-reduces-downtime&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;12 - It\\u2019s an accident-free workplace&quot;,&quot;value&quot;:&quot;12-its-an-accident-free-workplace&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Change resistance is inevitable&quot;,&quot;value&quot;:&quot;change-resistance-is-inevitable&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;10 TIPS TO REDUCE CHANGE RESISTANCE&quot;,&quot;value&quot;:&quot;10-tips-to-reduce-change-resistance&quot;,&quot;isDelete&quot;:true},{&quot;label&quot;:&quot;Material handling system part of a lean manufacturing journey&quot;,&quot;value&quot;:&quot;material-handling-system-part-of-a-lean-manufacturing-journey&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Flexpipe tube and joint modular structures examples&quot;,&quot;value&quot;:&quot;flexpipe-tube-and-joint-modular-structures-examples&quot;,&quot;isDelete&quot;:false},{&quot;label&quot;:&quot;Key takeaways&quot;,&quot;value&quot;:&quot;key-takeaways&quot;,&quot;isDelete&quot;:false}]\" data-smooth=\"true\" data-top-offset=\"-225\"><div class=\"eb-toc__list-wrap\"><ul class='eb-toc__list'><li><a href=\"#about-leslie-pickering\">About Leslie Pickering<\/a><li><a href=\"#the-5-trends-changing-the-industry\">The 5 trends changing the industry<\/a><li><a href=\"#further-consolidation\">Further consolidation?<\/a><li><a href=\"#a-new-major-player-in-the-usa\">A new major player in the USA<\/a><li><a href=\"#why-go-to-such-an-effort-to-become-lean\">Why go to such an effort to become Lean?<\/a><ul class='eb-toc__list'><li><a href=\"#lean-manufacturings-presence-in-the-industry-at-a-glance\">Lean manufacturing\u2019s presence in the industry at a glance<\/a><li><a href=\"#upper-management-in-the-lean-integration-process\">Upper management in the Lean integration process<\/a><li><a href=\"#8-manufacturing-wastes\">8 manufacturing wastes<\/a><\/li><\/ul><li><a href=\"#the-12-achievements-of-a-lean-factory-after-a-great-a-lean-journey\">The 12 achievements of a lean factory after a great a lean journey<\/a><ul class='eb-toc__list'><li><a href=\"#1-a-pull-system-is-used-for-the-production-system\">1 &#8211; A pull system is used for the production system<\/a><li><a href=\"#2-standardized-work-in-all-work-cells\">2 &#8211; Standardized work in all work cells<\/a><li><a href=\"#3-changeover-time-is-limited-to-10-minutes\">3 &#8211; Changeover time is limited to 10 minutes<\/a><li><a href=\"#4-one-piece-flow-is-in-place-throughout-the-plant\">4 &#8211; One-piece flow is in place throughout the plant<\/a><li><a href=\"#5-poka-yoke-helps-to-make-work-easier-and-improves-quality\">5 &#8211; Poka-yoke helps to make work easier and improves quality<\/a><li><a href=\"#6-visual-control-to-help-team-leaders\">6 &#8211; Visual control to help team leaders<\/a><li><a href=\"#7-a-sustainable-5s-program\">7 &#8211; A sustainable 5S program<\/a><li><a href=\"#8-inventory-management-is-done-visually\">8 &#8211; Inventory management is done visually<\/a><li><a href=\"#9-there-is-a-company-wide-kaizen-program\">9 &#8211; There is a company-wide kaizen program<\/a><li><a href=\"#10-training-programs-are-ahead-of-the-competitions\">10 &#8211; Training programs are ahead of the competition\u2019s<\/a><li><a href=\"#11-a-preventive-maintenance-program-reduces-downtime\">11 &#8211; A preventive maintenance program reduces downtime<\/a><li><a href=\"#12-its-an-accident-free-workplace\">12 &#8211; It\u2019s an accident-free workplace<\/a><\/li><\/ul><li><a href=\"#change-resistance-is-inevitable\">Change resistance is inevitable<\/a><li><a href=\"#material-handling-system-part-of-a-lean-manufacturing-journey\">Material handling system part of a lean manufacturing journey<\/a><ul class='eb-toc__list'><li><a href=\"#flexpipe-tube-and-joint-modular-structures-examples\">Flexpipe tube and joint modular structures examples<\/a><\/li><\/ul><li><a href=\"#key-takeaways\">Key takeaways<\/a><\/ul><\/div><\/div><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:30%\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"311\" height=\"336\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/01-Photo_et_citation_de_Leslie-311x336px-ANG.jpg\" alt=\"\" class=\"wp-image-23254\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/01-Photo_et_citation_de_Leslie-311x336px-ANG.jpg 311w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/01-Photo_et_citation_de_Leslie-311x336px-ANG-22x24.jpg 22w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/01-Photo_et_citation_de_Leslie-311x336px-ANG-33x36.jpg 33w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/01-Photo_et_citation_de_Leslie-311x336px-ANG-44x48.jpg 44w\" sizes=\"auto, (max-width: 311px) 100vw, 311px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:70%\">\n<h2 class=\"wp-block-heading\">About Leslie Pickering<\/h2>\n\n\n\n<p>Leslie A. Pickering is the co-owner of&nbsp;<strong><a href=\"https:\/\/quadrant5c.com\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Quadrant5<\/a><\/strong>, a consulting firm located in San Francisco, specialized in Lean transformation. Leslie brings over 40 years of experience in international process improvement, manufacturing and operations. He is a recognized&nbsp;<em>Toyota Production System<\/em>&nbsp;(TPS) specialist who has implemented successful transformation methodologies within the packaging, beverages, large warehousing, plastics and automotive industries.<\/p>\n\n\n\n<p>Providing an overview of the corrugated and packaging industry, Leslie eloquently states, \u201cAmazon and the Internet sales are changing the market. We are making more boxes than ever, and it has to be done quickly! The Internet brought a new time constraint.\u201d<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">The 5 trends changing the industry<\/h2>\n\n\n\n<p>In 2016,&nbsp;<strong>corrugated industry shipments rose by 2.1%.<\/strong>&nbsp;Furthermore, according to&nbsp;<a href=\"https:\/\/www.smithers.com\/resources\/2019\/jan\/trends-changing-the-corrugated-packaging-market\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Simether Pira\u2019s report<\/a>, e-commerce will help the sector grow around 3.7% annually and is expected to reach 300 billion in 2023. There are 5 prevailing trends in the corrugated packaging market:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>e-commerce with an estimated growth of 20% per year for the next 3 years.<\/li>\n\n\n\n<li>box-on-demand platforms driven by e-commerce such as Amazon.<\/li>\n\n\n\n<li>sustainability especially with regards to corrugated products.<\/li>\n\n\n\n<li>retail-ready packaging such as meal kit services.<\/li>\n\n\n\n<li>digital printing advancements.<\/li>\n<\/ul>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000.jpg\" alt=\"Operator schedule computer station eliminating paper for HP 17000\" class=\"wp-image-23272\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/operator-schedule-computer-station-eliminating-paper-for-HP-17000-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><figcaption class=\"wp-element-caption\">Operators now have their schedule on the main console HP 17000, eliminating the need for a paper scheduling system. By keeping the digital environment up to date, more corrugators can manufacture packaging with no tooling.<\/figcaption><\/figure>\n<\/div>\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Further consolidation?<\/h2>\n\n\n\n<p>There are 2,000 businesses currently active within the corrugated box industry in the USA, which employs over 141,000 people. The four largest manufacturers have 33.1% share of the industry, led by WestRock. Even if the corrugated box industry has been consolidating itself since 2016, from 690 plants to 465 corrugator plants, according to Fibre Box Association, Leslie Pickering is expecting more and more consolidation over the next five years within the market.<\/p>\n\n\n\n<p>&#8220;I\u2019m expecting more and more consolidation over the next years.&#8221;<br>Leslie Pickering \u2013&nbsp;<strong>Co-owner of Quadrant5<\/strong><\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"252\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith.jpg\" alt=\"DS Smith Packaging System Machinery\" class=\"wp-image-23275\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith-768x238.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith-375x116.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith-24x7.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith-36x11.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/systems-en-bref-ds-smith-48x15.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">A new major player in the USA<\/h2>\n\n\n\n<p>According to Mr. Pickering, the market will change even more the potential with the arrival of a major player from Europe, BS Smith.&nbsp;<strong>\u201cThey come with best practices and will force the industry to get better\u201d<\/strong>&nbsp;DS Smith is among the top six vendors in Europe with Georgia-Pacific, International Paper, Mondi, Smurfit Kappa and WestRock.<\/p>\n\n\n\n<p>DS Smith has already moved into the US market in 2017 by buying 80% of Interstate Resources and its 24 production sites. He continues,&nbsp;<strong>\u201cCorrugators will have to improve their operations with DS Smith in the way. They buy paper well, they manufacture very well and they have a new layout and new technologies.\u201d<\/strong><\/p>\n\n\n\n<p>&#8220;<q>I also visited 2 DS Smith plants in UK and I can confirmed that they are very efficient.<\/q>&#8220;<br>Pierre Audet \u2013&nbsp;<strong>President at Proden<\/strong>&nbsp;\u2013 A&nbsp;<a href=\"https:\/\/proden.com\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">flat and rotary die maker<\/a>&nbsp;based in Montreal, Toronto and Mexico.<\/p>\n\n\n\n<div class=\"wp-block-group is-style-container padding-left-20 padding-right-20 has-black-background-color has-background\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h3 class=\"wp-block-heading has-text-align-center has-white-color has-text-color has-link-color wp-elements-4c2b422704f9e60188660d4b8c701e34\">INCREASE PRODUCTIVITY WITH THE LEAN PHILOSOPHY<\/h3>\n\n\n\n<div class=\"wp-block-buttons is-content-justification-center is-layout-flex wp-container-core-buttons-is-layout-16018d1d wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.flexpipeinc.com\/ca_en\/case_study\/lean-philosophy-helped-increase-employee-productivity\/\">READ THE ARTICLE<\/a><\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Why go to such an effort to become Lean?<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">Lean manufacturing\u2019s presence in the industry at a glance<\/h3>\n\n\n\n<p><em>Toyota Production System<\/em>&nbsp;(TPS) introduced lean manufacturing principles in America, and it has widely spread among automakers since the 90s\u2014and now its suppliers. Leslie, who has been working with multiples industries, but mainly corrugators, maintains that&nbsp;<strong>the packaging and the corrugated industry is a decade behind other sectors<\/strong>&nbsp;such as the automotive.<\/p>\n\n\n\n<p>Corrugators spend millions to acquire machines but tend to minimize the impact of handling equipment, training and layout.&nbsp;<strong>These elements have a significant effect on the machines\u2019 productivity!<\/strong>&nbsp;Many manufacturers in the industry are focused on making boxes\u2014not on the processes of making boxes. This is the difference between an industrial environment and a visual environment. With the right processes and with people who are committed to them, quality is automatic.<\/p>\n\n\n\n<p><strong>The focus is too much on making boxes, and not enough on the processes of making boxes.<\/strong><\/p>\n\n\n\n<p>There are various reasons why companies begin Lean integration:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The impending closure of their day-to-day operations.<\/li>\n\n\n\n<li>Management thinks they are leaving money on the table and want to be more efficient by reducing costs.<\/li>\n\n\n\n<li>A move to a new facility or on the verge of implementing new important equipment.<\/li>\n\n\n\n<li>Working through important issues such as too much cash tied up in inventory, long lead times or quality.<\/li>\n<\/ul>\n\n\n\n<p>Well-run businesses that are good at manufacturing and have satisfactory sales might have margins ranging between 8.5 to 11%, and they still think that they are leaving 3% to 4% on the table. They need to improve processes and in general, efficiency to get the extra percentage points.&nbsp;<strong>People are focused on making boxes, but not enough on the processes<\/strong>, and that is the transition they must undertake. Other corrugators are very good at sales, have a great sales team but are not as strong on the production floor; they need to work on this to improve margins.<\/p>\n\n\n\n<p>Color Resolutions International, which provides ink to various packaging manufacturers, began its lean journey in 2002. The company\u2019s president and CEO, George Sickinger, explains, \u201c<strong>We were embarking on building a new facility and wanted to incorporate lean manufacturing into the new facility.<\/strong>&nbsp;We had an ideal opportunity to implement the process from building design through the manufacturing process; it was the right thing to invest in.\u201d<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Upper management in the Lean integration process<\/h3>\n\n\n\n<p>Leslie and his team usually start with an audit that will reveal where improvements are needed. Once the lean journey begins, a kickoff meeting chaired by the president is crucial to communicate why the mission is so important. All companies that went through such a transformation will tell you that&nbsp;<strong>the project owner and upper management must embrace the project to make it successful.<\/strong><\/p>\n\n\n\n<p>InteliCoat Technologies, a supplier of coated paper, film and speciality substrates for imaging technologies, integrated lean manufacturing in November 2007. A grant of nearly $400,000 provided by the state of Massachusetts helped fund the integration. Its past president, Meyer Weiss, explains,&nbsp;<strong>\u201cOur CEO has led this effort, without leadership at the top, the benefits of Lean cannot be fully realized.\u201d<\/strong><\/p>\n\n\n\n<p>When determining the area in which to implement lean manufacturing, in all cases, it should always start with an island of excellence. You could, for instance, focus your efforts on the machine, which requires the most significant investment or which has the most visibility because everyone is walking by it.<\/p>\n\n\n\n<p>A pilot plant implementation is usually carried out in companies with multiple plants. Once the implementation is finished in the first location, it can begin in the other plants&nbsp;<strong>where team members from the continuous improvement committee can train employees in the other plants.<\/strong><\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"557\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system.png\" alt=\"\" class=\"wp-image-23293\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system.png 1024w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system-768x418.png 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system-375x204.png 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system-24x13.png 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system-36x20.png 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/11\/8-manufacturing-wastes-according-to-the-toyota-production-system-48x26.png 48w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n<\/div>\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">8 manufacturing wastes<\/h3>\n\n\n\n<p>The Toyota Production System established 7 manufacturing wastes that don\u2019t add value to the customer. These manufacturing wastes are:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Unnecessary transportation,<\/li>\n\n\n\n<li>Excess inventory,<\/li>\n\n\n\n<li>Unnecessary motion,<\/li>\n\n\n\n<li>Waiting<\/li>\n\n\n\n<li>Overproduction<\/li>\n\n\n\n<li>Over-processing<\/li>\n\n\n\n<li>Defects<\/li>\n<\/ul>\n\n\n\n<p>However, we think it\u2019s essential to add an 8th waste:&nbsp;<strong>the waste of human potential.<\/strong>&nbsp;You\u2019ll find more on this proposed 8th waste later in the article.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote.jpg\" alt=\"\" class=\"wp-image-24282\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-excess-inventory-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:20%\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"313\" height=\"235\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/inventory.jpg\" alt=\"\" class=\"wp-image-23791\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/inventory.jpg 313w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/inventory-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/inventory-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/inventory-48x36.jpg 48w\" sizes=\"auto, (max-width: 313px) 100vw, 313px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Efficient supply management, coupled with reducing excess inventory is a significant advantage in the packaging industry. Not only does raw material take up much space but it also requires substantial capital investment. In an ideal scenario, the right quantity of raw material would be purchased for orders. However, there is a widespread fear of running out of raw materials; therefore, people buy more to avoid running out for the next jobs. A shift in paradigm would be very beneficial, according to Leslie.<\/p>\n<\/div>\n<\/div>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<div style=\"height:60px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote.jpg\" alt=\"\" class=\"wp-image-24294\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-unnecessary-movement-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:20%\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"313\" height=\"235\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/motion.jpg\" alt=\"\" class=\"wp-image-23794\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/motion.jpg 313w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/motion-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/motion-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/motion-48x36.jpg 48w\" sizes=\"auto, (max-width: 313px) 100vw, 313px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Unnecessary motion in material management is&nbsp;<strong>the most significant waste in the industry<\/strong>, according to Leslie. When operators walk around their machine for no valid reason, leave it to do paperwork, or check if the material is ready for the next run, they are not only doing unnecessary walking and moving but leave the quality for no one. This is especially problematic when working with older machines.<\/p>\n<\/div>\n<\/div>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<div style=\"height:60px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote.jpg\" alt=\"\" class=\"wp-image-24288\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-overproduction-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:20%\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"313\" height=\"235\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/overproduction.jpg\" alt=\"\" class=\"wp-image-23797\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/overproduction.jpg 313w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/overproduction-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/overproduction-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/overproduction-48x36.jpg 48w\" sizes=\"auto, (max-width: 313px) 100vw, 313px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Overproduction is a common practice in the industry. For most orders the \u201c+\/- 10%\u201d rule applies. For example,&nbsp;<strong>an order of 6,000 boxes could end up from 5,400 to 6,600 boxes.<\/strong>&nbsp;\u201cWhen you think about it, this is a terrible thing\u2014customers are overcharged to get what they want,\u201d explains Leslie. This 10% is billed to the client but is sometimes a point of negotiation.<\/p>\n<\/div>\n<\/div>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<div style=\"height:60px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote.jpg\" alt=\"\" class=\"wp-image-24300\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/manufacturing-waste-waiting-waterspider-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:20%\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"313\" height=\"235\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/waiting.jpg\" alt=\"\" class=\"wp-image-23782\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/waiting.jpg 313w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/waiting-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/waiting-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/waiting-48x36.jpg 48w\" sizes=\"auto, (max-width: 313px) 100vw, 313px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Waiting for the next order or material such as paper, tooling, ink or paperwork is another big waste. Employees or operators who are in \u201cwaiting\u201d mode&nbsp;<strong>represent an enormous waste of time and generates no added value for the customer.<\/strong>&nbsp;Time is precious on a production line: if a part needs to be changed, a machine needing a minor repair, poorly explained instructions for the next job or a missing tool that should be within reach, these all steal away precious minutes.<\/p>\n<\/div>\n<\/div>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<div style=\"height:60px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group is-style-container padding-left-20 padding-right-20 has-black-background-color has-background\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h3 class=\"wp-block-heading has-text-align-center has-white-color has-text-color has-link-color wp-elements-e55d3255f630e74375735825bf7b0455\">ROLE OF THE WATER SPIDER IN A LEAN STRUCTURE<\/h3>\n\n\n\n<div class=\"wp-block-buttons is-content-justification-center is-layout-flex wp-container-core-buttons-is-layout-16018d1d wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.flexpipeinc.com\/ca_en\/role_of_waterspider-2\">READ THE ARTICLE<\/a><\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">The 12 achievements of a lean factory after a great a lean journey<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">1 &#8211; A pull system is used for the production system<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\">\n<figure class=\"wp-block-image size-full figure-remove-margin\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"779\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper.jpg\" alt=\"\" class=\"wp-image-24014\" title=\"\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper-768x735.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper-375x359.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper-24x24.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper-36x34.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-kanban-system-for-printing-paper-48x46.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>The pull system is in place throughout the entire production process. There are clear visuals all over the plant to show the production\u2019s progress. Production levels are periodically adjusted to reflect customer orders. Kanban rules are in place and followed. Also, the Kanban quantity per container is minimal.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">2 &#8211; Standardized work in all work cells<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\">\n<figure class=\"wp-block-image size-full figure-remove-margin\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote.jpg\" alt=\"\" class=\"wp-image-24306\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/standardized-work-script-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Work is well balanced, with no wait time during each cycle. Work instructions target cycle and hourly production; they are tracked, and all employees are familiar with them. Work instructions are followed throughout the plant and are periodically checked and updated. In general, standard work is simple and makes the job more accessible to workers such as other operators, supervisors and even forklift drivers<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">3 &#8211; Changeover time is limited to 10 minutes<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\">\n<figure class=\"wp-block-image size-full figure-remove-margin\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote.jpg\" alt=\"\" class=\"wp-image-24222\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-cart-one-job-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>The changeover team must include the operators, and the changeover process must be done as quickly as possible (ideally, in less than 10 minutes). The process is standardized throughout the plant. A showcase cell exists, and kaizen events frequently occur to improve changeover time. There is a good ratio between changeover time and production. The machine assignment is as clear as the production schedule. The offline setup and activities are maximized without stopping the machinery. Jogs, tool dies, and other pieces of equipment are color-coded.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">4 &#8211; One-piece flow is in place throughout the plant<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote.jpg\" alt=\"\" class=\"wp-image-24228\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/obeya-room-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>All processes are clear: products, components, and raw material move from one process to the next one piece at a time (one-piece flow). The material flows in and out of the work cell on a scheduled conveyance route. Each process is clearly linked to the following one, and it\u2019s easy to follow the material flow. Ultimately, secondary processes (paint, outsourcing, etc.) are tied together plant-wide.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">5 &#8211; Poka-yoke helps to make work easier and improves quality<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote.jpg\" alt=\"\" class=\"wp-image-24234\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/poka-yoke-corrugated-packaging-industry-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>The various pieces of equipment have Poka-yoke devices, thus making it impossible to bypass. Poka-yoke is simple, robust, reliable and cost-effective. They undergo regular checks and tests, and are labeled, color-coded and mapped.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">6 &#8211; Visual control to help team leaders<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote.jpg\" alt=\"\" class=\"wp-image-24246\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-control-packaging-industry-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>There is a clear understanding of what normal and abnormal situations consist of. There is a signal system (light\/alarm) in place which is understood by operators and the management team. When an abnormal situation occurs, procedures are in place, and the team leader responds quickly. For example, in quality control, it\u2019s easy to detect an abnormal situation with a visual indicator (shown in the picture below). If no visual indicator is installed over the top of the loads, this is an abnormal situation and action must be taken.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">7 &#8211; A sustainable 5S program<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote.jpg\" alt=\"\" class=\"wp-image-24240\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-board-tooling-station-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>There is a place for everything, and everything is in its place with the 5S program. All employees understand the principle and its benefits. The implementation of 5S is obvious throughout the entire plant and office. 5S is sustained by individual team members using visual management of tools and routine schedule.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">8 &#8211; Inventory management is done visually<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote.jpg\" alt=\"\" class=\"wp-image-24252\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/first-in-first-out-inventory-management-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>All inventory locations are established and identified. Racks and containers are labeled, and the \u201cFirst in \u2013 First out\u201d (FIFO) principle is in place and upheld. Inventory levels (min\/max) are regularly adjusted to account for usage fluctuations. Visuals controls are used to prevent mixed parts and overflow.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">9 &#8211; There is a company-wide kaizen program<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote.jpg\" alt=\"\" class=\"wp-image-24258\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/kaizen-event-moonshine-shop-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>The company\u2019s culture acknowledges the benefits of kaizen and management supports the team dedicated to its activities and initiatives. Kaizen activities are scheduled, tracked and tied to company goals and objectives.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">10 &#8211; Training programs are ahead of the competition\u2019s<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"756\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote.jpg\" alt=\"\" class=\"wp-image-24270\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote-768x712.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote-375x348.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote-24x22.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote-36x33.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/training-programs-better-than-competition-quote-48x45.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>There is a formal training program for new hires, and team members are trained to be multiskilled. A team member development\/career path program exists. The training status for all is posted, and refresher training is scheduled regularly.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">11 &#8211; A preventive maintenance program reduces downtime<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"756\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote.jpg\" alt=\"\" class=\"wp-image-24264\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote-768x712.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote-375x348.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote-24x22.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote-36x33.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/preventive-maintenance-quote-48x45.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Time is allocated for total preventive maintenance (TPM) throughout the plant. The operator who is involved in daily maintenance is an integral part of the process. A tooling calibration program is in place to ensure equipment accuracy. Downtime is tracked and analyzed. Root causes of problems are determined, and countermeasures are incorporated into preventive maintenance.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">12 &#8211; <strong>It\u2019s an accident-free workplace<\/strong><\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:50%\"><div class=\"wp-block-image figure-remove-margin\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"815\" height=\"485\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote.jpg\" alt=\"\" class=\"wp-image-24276\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote.jpg 815w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote-768x457.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote-375x223.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote-36x21.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/floor-marking-preventing-fork-lift-injury-quote-48x29.jpg 48w\" sizes=\"auto, (max-width: 815px) 100vw, 815px\" \/><\/figure>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>There is a written safety program that is familiar to all team members and collectively enforced. The safety coordinator participates in the daily audit. Accidents are compiled: countermeasures are adopted and analyzed. Management and visitors adhere to the safety program.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Change resistance is inevitable<\/h2>\n\n\n\n<p>Any good management team knows that its company\u2019s employees are a vital element to achieve success. A lean manufacturing integration requires that everyone be on board with the process and work together, so it successfully comes into fruition.<\/p>\n\n\n\n<p>All the employees got behind the idea that lean manufacturing was going to be an all-around plus for everyone involved, and then&nbsp;<strong>it just naturally permeated the company\u2019s culture.<\/strong>&nbsp;The union played a critical role, states Meyer Weiss, where \u201cFor our union employees, in particular, it is clear that the lean culture is saving jobs and making us more competitive. The union leadership has welcomed Lean and has been fully engaged in promoting the benefits to the employees and the company.\u201d He continues \u201cemployees have to see what\u2019s in it for them. For example, making the job easier, making the vacation rotation easier, and lastly saving jobs, etc.\u201d<\/p>\n\n\n\n<p>Leslie Pickering adds, \u201cYou need to show that it\u2019s not going to be another flavour of the month.\u201d<\/p>\n\n\n\n<p>InteliCoat, Heritage Paper, President Container or Royal Container are examples of companies that brought in several consultants to help develop the implementation\u2019s steps and train employees. Outside experts such as lean consultants challenged the status quo and current paradigms.<\/p>\n\n\n\n<p>Along with Q5 consulting group, Royal Containers employees have stepped up to the plate and have taken responsibility and ownership of the exciting revamp. A long-time Royal employee, Dan Rudnicki, has been leading the internal team to ensure targets are met. A great consulting partner knows how to do the job, and they are very hands-on\u2014they don\u2019t just create great PowerPoint presentations!<\/p>\n\n\n\n<p>Kim Nelson, President of Royal Containers, located in southern Ontario, started their initial lean implementation in 2019 to be completed later in the year. The second lean integration will begin afterwards in their other plant in nearby Brampton.<\/p>\n\n\n\n<p>They are targeting cutting costs in operations, improving quality with better calibration and achieving faster turnaround time with the implementation of streamlined processes.&nbsp;<strong>\u201cWe embarked on a CI plan to change the entire plant environment. So far, we are right on track and loving every minute of it!\u201d<\/strong>&nbsp;said Mrs. Nelson.<\/p>\n\n\n\n<div class=\"wp-block-group is-style-container padding-left-20 padding-right-20 has-black-background-color has-background\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h3 class=\"wp-block-heading has-text-align-center has-white-color has-text-color has-link-color wp-elements-11f221fa74f8ba73a05525abc3549079\">10 TIPS TO REDUCE CHANGE RESISTANCE<\/h3>\n\n\n\n<div class=\"wp-block-buttons is-content-justification-center is-layout-flex wp-container-core-buttons-is-layout-16018d1d wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.flexpipeinc.com\/ca_en\/reduce-change-resistance\/\">READ THE ARTICLE<\/a><\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Material handling system part of a lean manufacturing journey<\/h2>\n\n\n\n<p>Traditionally, the industry has been using either wood or welded structures. Occasionally, material handling equipment may be supplied by machinery (OEM), and it will be used as-is.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"323\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart.jpg\" alt=\"\" class=\"wp-image-24186\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart-768x305.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart-375x149.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart-36x14.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/rotary-dies-cart-48x19.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>These die transfer carts for rotary dies, flat dies and printing plates have been on the market and are widely used.<\/p>\n\n\n\n<p>They are made of heavy-duty steel and fit DRO, EVOL rotary dies, and Platen and Bobst flat dies.<\/p>\n\n\n\n<p>The picture is from Wagner Die Supply, a diemaker with several locations in the USA.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"539\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart.jpg\" alt=\"\" class=\"wp-image-24189\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart-768x509.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart-375x248.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart-24x16.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart-36x24.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/printing-plates-standard-cart-48x32.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>Steel structures work for now, but when processes eventually change, they will no longer be adapted to the task at hand.<\/p>\n\n\n\n<p>If the material handling equipment is not supplied by OEM or is unsuitable, pipe and joint systems can be used to build a solution around the machine.<\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:20%\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"313\" height=\"235\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/unusedtalent.jpg\" alt=\"\" class=\"wp-image-23803\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/unusedtalent.jpg 313w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/unusedtalent-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/unusedtalent-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/unusedtalent-48x36.jpg 48w\" sizes=\"auto, (max-width: 313px) 100vw, 313px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>\u201cWe usually buy nothing from Uline for carts or racking for 2 reasons: first, there\u2019s no competitive advantage: your competition can buy it. And second, it\u2019s never ideally sized for the job, so you have to conform to it instead of having the structure conform to you and the work,\u2019\u2019 explains Leslie. We have been using pipe and joint for 10 years. I can change a pipe and joint structure in 30 minutes. Problem in the morning and solution in the afternoon!\u201d<\/p>\n\n\n\n<p><a href=\"https:\/\/www.youtube.com\/watch?v=7a-Op807Vqk&amp;t=\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Tap into your employees\u2019 creativity<\/a>&nbsp;with the pipe and joint system and avoid the 8th waste: the loss of good employee ideas.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Flexpipe tube and joint modular structures examples<\/h3>\n\n\n\n<p>Here are a few examples of modular tube and joint connector structures in use in a corrugated cardboard packaging manufacturing plant in Ontario.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry.jpg\" alt=\"\" class=\"wp-image-24207\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/operator-station-corrugated-industry-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>Operator station:<\/strong>&nbsp;this type of structure puts ergonomics at the forefront and helps to reduce body fatigue\u2014especially in hot weather. Process, jobs and requirements all change over time. So when a new job requires a new instruction booklet, for instance, we can alter the station to make the booklet easy to locate. Modular systems allow us to make quick changes at a low cost.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over.jpg\" alt=\"\" class=\"wp-image-24204\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/one-job-one-cart-easy-change-over-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>One cart \u2013 one job :<\/strong>\u00a0In the podcast\u00a0<strong><em><a href=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/01\/PODCAST-Learn-how-lean-manufacturing-helps-corrugators-adapt-to-the-changes-in-their-industry-with-Leslie-Pickering-Q5.mp3\" target=\"_blank\" rel=\"noreferrer noopener\">Learn how lean manufacturing helps corrugators adapt to the changes in their industry with Leslie Pickering<\/a><\/em><\/strong>, Leslie explains the ideal setup where everything is on the cart for the job. \u201cWe have been using the 1 cart, 1 job concept for 20 years now. From 10 meters away, I can see if everything is there for the next job. The operator can examine the cart while the machine is running and then ask the right questions such as \u201cwhy the ink is not there?\u201d If the schedule changes and the carts for the next 3 jobs are ready, usually the change can be accommodated. You should aim to reduce downtime and have machines running longer; the cost of the machine per minute is important!\u201d<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container.jpg\" alt=\"single-level Flexpipe 5S mobile cart made with blue steel tubes and black connectors and joints.\" class=\"wp-image-48504\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-500x375.jpg 500w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-800x600.jpg 800w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2023\/09\/5s-board_president-container-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>5S boards:<\/strong>&nbsp;Important tools are usually located in toolboxes. Though OEM supply toolboxes, it\u2019s best to have them all displayed on a 5S board to see if any tools are missing, as opposed to them being jumbled in a box.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"654\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en.jpg\" alt=\"\" class=\"wp-image-14940\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en-768x617.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en-375x301.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en-24x19.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en-36x29.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2019\/10\/3-essential-elements-for-visual-control-shadow-board-en-48x39.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>Visual management needs 3 elements:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>ID tag<\/li>\n\n\n\n<li>Color<\/li>\n\n\n\n<li>Tool\u2019s shadow<\/li>\n<\/ul>\n\n\n\n<p>These are core to having the system working efficiently and sustainably over time, both in the office and in the production area. Many operators don\u2019t have what they need on hand.&nbsp;<strong>A tool change is like a race car tire change: 1 shift must have it all.<\/strong>&nbsp;Every morning do a visual check to see if your team has everything it needs.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"886\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop.jpg\" alt=\"\" class=\"wp-image-24219\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop-768x836.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop-375x408.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop-22x24.jpg 22w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop-33x36.jpg 33w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/royal-containers-moonshine-shop-44x48.jpg 44w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong><a href=\"https:\/\/www.flexpipeinc.com\/ca_en\/moonshine-shops\/\">Moonshine shop<\/a>:<\/strong>&nbsp;This is where the magic happens; it\u2019s where ideas pitched by operators come to life. Whether from a sketch or a CI (\u201cContinuous Improvement\u201d) challenge, make sure to confirm and thoroughly understand what the operator wants and then build a structure to meet the needs expressed in the sketch. A CI workshop is meant to empower workers. In it, there is everything to develop solutions to problems! A quick solution implemented in the production area will help make boxes faster and cheaper. As Leslie aptly puts it, \u201cProblems in the morning, solution in the afternoon!\u201d<\/p>\n\n\n\n<p><strong>Who can assemble?<\/strong>&nbsp;Most operators can do it \u2013 it\u2019s relatively easy. Continuous improvement team members can also help.<\/p>\n\n\n\n<p>You want to solicit ideas from the people directly involved in day-to-day operations. Remember, not all ideas generated from staff will be great, but you can participate in the process and teach them the makings of a great idea.<\/p>\n\n\n\n<div class=\"hs-cta-embed hs-cta-simple-placeholder hs-cta-embed-194885758874\"\n  style=\"max-width:100%; max-height:100%; width:1000px;height:379.25px\" data-hubspot-wrapper-cta-id=\"194885758874\">\n  <a href=\"https:\/\/cta-service-cms2.hubspot.com\/web-interactives\/public\/v1\/track\/redirect?encryptedPayload=AVxigLJBcFECcip1T1iD6PmiJlAVL8AViBs1Ap4XaFw9vMRJz6nhfKqqQqS1uB1%2FPErR3sj0XE%2Ft8k%2FxgvC2%2BUcV78bpXszKOHrBZXu3zynFxKpjwzgD0IYP4dJdquNtEmdkEzbrFuP6MYNcBq1j8qsL21CQcDjlTB6YDLszkfOCIjVYxMGUjf%2Fk8dVtkrlp9bCpQcdTeE0fEVNAbkAHHynLcUezM65y%2By5kVndiHg%3D%3D&#038;webInteractiveContentId=194885758874&#038;portalId=2641120\" target=\"_blank\" rel=\"noopener\" crossorigin=\"anonymous\">\n    <img decoding=\"async\" alt=\"Build Your Own Moonshine Shop from Scratch This checklist includes everything you need to set up a lean, efficient Moonshine Shop&mdash;tools, parts, and components all in one place to kickstart your project. &nbsp;\" loading=\"lazy\" src=\"https:\/\/no-cache.hubspot.com\/cta\/default\/2641120\/interactive-194885758874.png\" style=\"height: 100%; width: 100%; object-fit: fill\"\n      onerror=\"this.style.display='none'\" \/>\n  <\/a>\n<\/div>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"350\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c.jpg\" alt=\"\" class=\"wp-image-24198\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c-768x330.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c-375x161.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c-36x15.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-ink-chamber-before-after-made-by-quadrant-5c-48x21.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><figcaption class=\"wp-element-caption\">Are you still cleaning chambers on ink buckets? Our Chamber Blade Carts reduce TPM time and operator stress on the body, ensuring a better, safer way to do this important task.<\/figcaption><\/figure>\n<\/div>\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"350\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c.jpg\" alt=\"corrugated industrie workstation made by quadrant\" class=\"wp-image-24195\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c-768x330.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c-375x161.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c-36x15.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/before-after-corrugated-industrie-workstation-5s-made-by-quadrant-5c-48x21.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><figcaption class=\"wp-element-caption\">Moving out the old industrial standard table replacing it with the Team\u2019s new mobile workstation and ink monitoring station for a Bobst Martin 1228 FFG.<\/figcaption><\/figure>\n<\/div>\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"350\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c.jpg\" alt=\"\" class=\"wp-image-24201\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-768x330.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-375x161.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-36x15.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/corrugated-industry-roraty-die-management-before-after-made-by-quadrant-5c-48x21.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><figcaption class=\"wp-element-caption\">Have the tools arrived for that hot job? Can\u2019t find tools? Are tools delivered to the wrong door? See before and after to make incoming\/outgoing of tooling a process.<\/figcaption><\/figure>\n<\/div>\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/shop.flexpipeinc.com\/kit-q5\" target=\"_blank\" rel=\"noopener\">SEE ALL ADVANTAGES OF THE KIT-Q5<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste.jpg\" alt=\"\" class=\"wp-image-24324\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/job-changeover-reduce-motion-manufacturing-waste-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>Presentation of specialized tools in the correct manner is important, especially when they are presented on a mobile cart. So they are moved to the optimal position,&nbsp;<strong>reducing waste of motion<\/strong>. Seconds saved here allow for many hours of additional run time because of reed job changeover techniques.<\/p>\n\n\n\n<p>Red and green wall color meaning:<\/p>\n\n\n\n<p><strong>GREEN<\/strong>&nbsp;indicates new tooling for the facility, here it is delivered by the supplier. It is the only place the OEM can deposit the new tooling plus it is the only location anyone has to look for the new tool delivery.<\/p>\n\n\n\n<p><strong>RED<\/strong>&nbsp;indicates that the tool has a problem other than needs repair or modification. The facility places the tools for repair in the red area and places the corresponding paperwork into one of the four bins on the right, depending on which supplier will do the work.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"350\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint.jpg\" alt=\"\" class=\"wp-image-24312\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint-768x330.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint-375x161.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint-24x10.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint-36x15.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/stackable-system-for-a-smaller-footprint-48x21.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>Addresses&nbsp;<strong>safety and transportation waste<\/strong>. The older system in the rear results in wood carts being stored on end. This causes a safety issue and possible injury to a team member from splinters.&nbsp;<strong>A stackable system allows you to store more carts in a smaller footprint<\/strong>, easy to move by team member not needed a fork truck and no possibility of splinters.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"611\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste.jpg\" alt=\"\" class=\"wp-image-24327\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste-768x576.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste-375x281.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste-24x18.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste-36x27.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/mobile-material-carts-to-reduce-motion-manufacturing-waste-48x36.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>Mobile Material Carts<\/strong>&nbsp;\u2013 These allow several operational advantages. You can take the cart to the replenishment area, fill it with four bobbins and return,&nbsp;<strong>removing the need for two trips by the operator (waster of motion)<\/strong>. It ensures you have the correct material because the cart is designed to accommodate the correct item in the correct amounts (inventory management).<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"1086\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station.jpg\" alt=\"\" class=\"wp-image-24321\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station-768x1025.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station-375x500.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station-18x24.jpg 18w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station-27x36.jpg 27w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-tooling-station-36x48.jpg 36w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p>Ensuring you have ALL the correct hand tools visible allows you to see immediately if any one of them is needed.&nbsp;<strong>It reduces waste (time and motion) looking for items<\/strong>&nbsp;and removes the need for expensive toolboxes.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"1227\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station.jpg\" alt=\"\" class=\"wp-image-24318\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station-768x1158.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station-375x565.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station-16x24.jpg 16w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station-24x36.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/5s-cleaning-station-32x48.jpg 32w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>Cleaning Stations<\/strong>&nbsp;\u2013 Ensuring each process has the important and appropriate tools for clean up,&nbsp;<strong>reduces time looking for tools<\/strong>&nbsp;and ensures that the process has the correct tools.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"814\" height=\"1085\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper.jpg\" alt=\"\" class=\"wp-image-24330\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper-768x1024.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper-375x500.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper-18x24.jpg 18w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper-27x36.jpg 27w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2020\/12\/visual-management-workstation-printing-paper-36x48.jpg 36w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/figure>\n<\/div>\n\n\n<p><strong>Operator Stations<\/strong>&nbsp;\u2013 Correct sizing of the worktop prevents additional items from being stored there. Using yellow and red colors to indicate condition early and&nbsp;<strong>gives you time to make a countermeasure<\/strong>&nbsp;before an issue presents itself. Using a skeleton approach also prevents areas from becoming cluttered with items not necessary at the process.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Key takeaways<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>E-commerce growth and market consolidation<\/strong> (e.g., new European entrants) are pressuring plants to be faster, more flexible, and more digital.<\/li>\n\n\n\n<li><strong>Shift the focus<\/strong> from \u201cmaking boxes\u201d to optimizing the <em>process<\/em> of making boxes; aim for a visual, standard, and well-managed environment.<\/li>\n\n\n\n<li><strong>Tackle the 8 wastes<\/strong>\u2014especially unnecessary motion, waiting, and overproduction driven by \u201c\u00b110%\u201d norms\u2014and don\u2019t ignore the 8th waste: unused human potential.<\/li>\n\n\n\n<li><strong>Leadership matters :<\/strong> launch with a president-led kickoff, start with an \u201cisland of excellence,\u201d and scale after proving the model.<\/li>\n\n\n\n<li><strong>Hallmarks of a lean factory :<\/strong> pull system, standardized work, &lt;10-minute changeovers, one-piece flow, poka-yoke, visual control, 5S, visual inventory\/FIFO, kaizen culture, robust training, TPM, and safety.<\/li>\n\n\n\n<li><strong>Treat material handling as strategic :<\/strong> modular pipe-and-joint solutions (one cart\u2013one job, 5S boards, \u201cmoonshine\u201d shop) speed changeovers and empower operators.<\/li>\n\n\n\n<li><strong>Expected impact :<\/strong> lower downtime, faster turnarounds, better quality, safer and more ergonomic work.<\/li>\n<\/ul>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"hs-cta-embed hs-cta-simple-placeholder hs-cta-embed-194828777378\"\n  style=\"max-width:100%; max-height:100%; width:1200px;height:321.984375px\" data-hubspot-wrapper-cta-id=\"194828777378\">\n  <a href=\"https:\/\/cta-service-cms2.hubspot.com\/web-interactives\/public\/v1\/track\/redirect?encryptedPayload=AVxigLIfFTD8rLHilqdXo3TZPB2QZLjlkNbrxj4LUTBeG8aZ1Bnj1P5JPPwjEfh5zWj0HQwaD5Dvc8ZPnFfYiaUxDQnectmmV04ehDGpiuABK29SQNc4xq9zZ%2F6W5xfV61uloGAglseoKBj5wVuABrxIqHbJAIhCvCNw7YF9Ym1p7FnwlJsPXMflcnunafdUKzXR%2B73NhVG1L43wgFPEKLEl&#038;webInteractiveContentId=194828777378&#038;portalId=2641120\" target=\"_blank\" rel=\"noopener\" crossorigin=\"anonymous\">\n    <img decoding=\"async\" alt=\"Request Your Free Flexpipe Sample Kit See the quality for yourself. Get a free box with pipes, joints, and roller tracks to test our system&rsquo;s fit, finish, and compatibility in your own facility. &nbsp;\" loading=\"lazy\" src=\"https:\/\/no-cache.hubspot.com\/cta\/default\/2641120\/interactive-194828777378.png\" style=\"height: 100%; width: 100%; object-fit: fill\"\n      onerror=\"this.style.display='none'\" \/>\n  <\/a>\n<\/div>\n<\/div><\/div>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>About Leslie Pickering Leslie A. Pickering is the co-owner of&nbsp;Quadrant5, a consulting firm located in San Francisco, specialized in Lean transformation. Leslie brings over 40 years of experience in international process improvement, manufacturing and operations. He is a recognized&nbsp;Toyota Production System&nbsp;(TPS) specialist who has implemented successful transformation methodologies within the packaging, beverages, large warehousing, plastics &hellip; <a href=\"https:\/\/www.flexpipeinc.com\/ca_en\/corrugated-packaging-material-handling\/\">Continued<\/a><\/p>\n","protected":false},"author":7,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"_eb_attr":"","content-type":"","inline_featured_image":false,"sfsi_plus_gutenberg_text_before_share":"","sfsi_plus_gutenberg_show_text_before_share":"","sfsi_plus_gutenberg_icon_type":"","sfsi_plus_gutenberg_icon_alignemt":"","sfsi_plus_gutenburg_max_per_row":"","_eb_data_table":"","cybocfi_hide_featured_image":"","yasr_overall_rating":0,"yasr_post_is_review":"","yasr_auto_insert_disabled":"","yasr_review_type":"","footnotes":""},"class_list":["post-68257","page","type-page","status-publish","hentry"],"acf":[],"yasr_visitor_votes":{"stars_attributes":{"read_only":false,"span_bottom":false},"number_of_votes":0,"sum_votes":0},"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/pages\/68257","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/users\/7"}],"replies":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/comments?post=68257"}],"version-history":[{"count":1,"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/pages\/68257\/revisions"}],"predecessor-version":[{"id":70069,"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/pages\/68257\/revisions\/70069"}],"wp:attachment":[{"href":"https:\/\/www.flexpipeinc.com\/ca_en\/wp-json\/wp\/v2\/media?parent=68257"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}