Continuous Improvement in Action: Small Changes, Big Results
Continuous improvement isn't always about massive transformations. More often, it's the small, thoughtful changes that eliminate frustration, save time, and make daily work easier for the people on the floor.
Recent events led by the Continuous Improvement team have focused on exactly that, finding opportunities to simplify processes, improve organization, and create more efficient workflows across production.
Smoother Production on the 5136 Line
During the recent 5136 Line Balancing Event, the team focused on identifying opportunities to remove waste and improve efficiency throughout the assembly process.
One improvement came from something many assemblers know all too well: staple jams. After evaluating performance, the team identified a new staple supplier that significantly reduced jamming issues. While the change may seem small, it saves valuable time during production and is projected to reduce cycle time by approximately five seconds per unit.
The team also tackled another opportunity by eliminating the need to manually cut 5136 Insulator Sleeves to length. A change request was submitted to update sleeve lengths, removing an unnecessary step from the process and helping streamline assembly.
Special recognition goes to Brett Sanford for his leadership during the event and to Nick Braunsteiner for his contributions in identifying and implementing improvements.
Improving Weld Kitting and Material Flow
The Weld Kitting Event focused on making it easier for team members to find what they need and keep production moving efficiently.
One major accomplishment was updating the Weld Kitters Pick List to align with DOP IDs. Prior to DOP implementation, the list was based on Build Schedule Numbers through a custom process. The team successfully remapped and fine-tuned the system to better support current operations, creating a more reliable and user-friendly process for the floor.
Additional improvements included updated staging signage for formed parts. New laminated DOP-specific signs with 3D-printed bases provide clearer identification and improve organization throughout the staging area.
The team also developed a new organizational layout for formed backs, with plans to establish clearly marked lanes to support visual management and improve material flow.
Thank you to Jacob Bradshaw for leading the effort, along with Matt Hutchins, Wyatt Bryant, and Nick Braunsteiner for their valuable contributions.
Making Fixtures Easier to Find
Finding the right fixture quickly can make a significant difference in keeping production on schedule.
During the Fixture Evaluation and 5S Event, the team organized and cleaned out fixture inventory while evaluating opportunities to improve accessibility and visibility.
A dedicated computer was installed to allow team members to quickly search for needed fixtures, reducing time spent locating critical equipment. The team also created an updated fixture spreadsheet designed to help assembler leads and stockmen quickly identify and locate the fixtures they need.
A special thank you goes to Jacob Bradshaw for leading the event and to Matt Bussard, whose input and hands-on involvement helped shape the updated fixture tracking process.
Building a Culture of 5S
One of the most impactful initiatives underway is the continued rollout of 5S across Final Assembly.
The program has now been implemented throughout 1st Shift Final Assembly, including Line 10 and the Test Switch Department. Daily audits are helping reinforce standards, maintain organization, and ensure improvements are sustained over time.
The Continuous Improvement team is currently developing the next phase of the rollout to bring the same process and consistency to 2nd Shift Final Assembly.
Led by Jacob Bradshaw and Brett Sandford, these efforts continue to build a stronger foundation for workplace organization, efficiency, and continuous improvement across the facility.
Progress Through Continuous Improvement
Whether it's reducing staple jams, improving visual management, simplifying material flow, or strengthening 5S practices, each improvement contributes to a safer, more efficient workplace.
These projects are a reminder that continuous improvement isn't about one big change, it's about hundreds of small improvements that add up to meaningful results. Thank you to everyone involved for their ideas, collaboration, and commitment to making Milbank better every day.